1-4T Manual (Old Models)

Preface
Thanks for selecting lonking forklifts.

In order to correctly use and maintain 1-4T counterbalanced electric forklift truck, this
Manual is made. This Manual introduces the performance of main components, inspection,
regulation, maintenance and safe driving guide, and it also includes proposal and
assistance for you. It’ll be very dangerous to perform improper operation, maintenance and
repair to the forklift, and severe casualty or even death will be probably caused, the
operator and repair and maintenance staff shall read through this Manual before starting
operation or repair and maintenance, and the forklift can be only used after the contents of
Manual are comprehended thoroughly.
With continual improvement of component and device, your forklift structure will be
probably changed, and the change won't be informed additionally.
The contents of this Manual will be changed due to continual improvement of products. In
order to better serve the customer, enhance product and service quality, please inform the
problems found during the process of using Longgong products and Operating Instruction
to our company by letter.
If you have problem, please contact China Lonking (Shanghai) Forklift Co., Ltd.
Lonking (Shanghai) Forklift Co., Ltd.

Nov, 2010
Address：196 Xinrun Road, Songjiang Industrial, Shanghai, China
http://www.lonking.cn
I
Contents
Chapter 1 Specification...............................................................................................3
Chapter 2 Use and safe operation precaution..............................................................9
1. Transportation.................................................................................................................... 9
2. Deposit...............................................................................................................................9
3. Preparative before operation..............................................................................................9
4. Drive precaution................................................................................................................ 9
5. Safety precaution............................................................................................................. 10
6. Daily Maintenance...........................................................................................................13
6.1 Maintenance summary...........................................................................................13
6.2 Startup....................................................................................................................13
6.3 Cooling system precaution.....................................................................................13
6.4 Oil, grease and antifreeze.......................................................................................14
6.5 Lubricating system.................................................................................................15
Chapter 3 Forklift Structure, principle, adjustment ,maintenance............................ 16
1. The power system............................................................................................................ 16
1.1 The engine............................................................................................................. 16
1.2 The engine parameters and applicable models...................................................... 17
1.3 Checking and adjusting of the engine....................................................................18
1.4 Fuel system............................................................................................................ 19
1.5 Accelerator pedal................................................................................................... 20
2 Clutch drive...................................................................................................................... 21
2.1 Overview................................................................................................................21
2.2 Maintenance...........................................................................................................23
3 Mechanical drive system.................................................................................................. 25
3.1 Summary................................................................................................................25
4 Hydraulic drive system..................................................................................................... 30
4.1 Summary................................................................................................................30
4.2 The torque converter.............................................................................................. 32
4.3 Hydraulic clutch.....................................................................................................33
4.4 Control valve, overflow valve and inching valve.................................................. 34
4.5 Transmission case.................................................................................................. 35
4.6 Oil feed pump........................................................................................................ 35
4.7 The oil channel system of the torque converter..................................................... 35
4.8 Towing of the breakdown forklift.......................................................................... 36
4.9 Port fitting, oil pressure、 oil temperature measurement..................................... 37
5. Drive axle........................................................................................................................ 38
5.1 Summary................................................................................................................38
5.2 Assemble procedure of the wheel hub................................................................... 40
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6. Steering system................................................................................................................41
6.1 Summary................................................................................................................41
6.2 Cycloid full-hydraulic steering control units......................................................... 42
6.3 Check the steering system after reassembling the steering system........................42
6.4 The steering system troubleshooting..................................................................... 43
6.5 Steering axle.......................................................................................................... 43
7. Brake system....................................................................................................................47
7.1 Summary................................................................................................................47
7.2 Maintenance...........................................................................................................56
8 .Lifting system.................................................................................................................. 62
8.1 Summary................................................................................................................62
8.2 Inner and outer mast.............................................................................................. 62
8.3 Carriage..................................................................................................................63
8.4 Position of roller wheel..........................................................................................63
8.5 Maintenance...........................................................................................................64
9. Hydraulic system............................................................................................................. 67
9.1 Summary................................................................................................................67
9.2 Main pump.............................................................................................................67
9.3 Multi-way valve and shunt valve...........................................................................68
9.4 The oil line of hydraulic system.............................................................................72
9.5Multi-way valve control..........................................................................................73
9.6 Lift cylinder........................................................................................................... 74
9.7 Governor valve...................................................................................................... 75
9.8 Tilt cylinder............................................................................................................76
9.9 Hydraulic oil tank.................................................................................................. 77
9.10 Maintenance of main oil pump............................................................................ 78
9.11 Trial run................................................................................................................80
9.12 Debugging guide..................................................................................................81
10. Liquefied gas system..................................................................................................... 83
10.1 Liquefied gas system composition of LPG forklift..............................................84
10.2 Cautions for LPG forklift operation.....................................................................90
11. Electrical system............................................................................................................ 91
11.1 Summary.............................................................................................................. 91
11.2 Description of operation...................................................................................... 91
2
Chapter 1 Specification
3
FD series
Model FD20(T) FD25(T) FD30(T) FD35(T)
Power form Diesel oil
Rated load (kg) 2000 2500 3000 3500
Load center (mm) 500
Self-weight of whole forklift (kg) 3550 3950 4360 4750
Axle load full load 4875/675 5775/775 6300/700 7000/900
(front/back)(kg) no-load 1420/2130 1520/2430 1600/2400 1100/2700
S Front wheel 970 1000
Track(mm)
P Rear wheel 980
L5 Shaft distance(mm) 1600 1700
X Front overhang(mm) 460 478
L4 Rear overhang(mm) 430 500 522 580
Overall size L1 Total length 3560 3630 3770 3843
(with forks) B Overall width 1150 1150 1225 1225
(mm) H6 Total height 2110 2110 2100 2100
H2 Free lifting height (mm) 140 165
Max. lifting height (mm) 3000
α/β Mast tilt angle (front/back)(°) 6/12
L3×W×T Fork size (mm) 1070×125×40 1070×125×40 1070×125×45 1070×125×50
Wa Min. Turn radius(mm) 2170 2240 2460 2520
Min. right-angle channel width
3830 3900 4155 4215
(mm)
Min. Ground m1 Mast 123 132
clearance(mm) m2 Frame 140 165
Max.Drive speed forward 20
（km/h） backward 20
Max.Lifting full load 430 410 430 380
speed(mm/s) no-load 460 460 420
Lower speed（mm）＜600
Max. gradeability % 20
Working tank capacity（L） 50 55
Fuel tank capacity（L） 50 60
H1 Overhead guard height(from
1000 990
face of seat)（mm）
4
LG series
Model LG15D LG20D LG20DT LG25D LG25DT
Rated load (kg) 1500 2000 2500
Self-weight of whole forklift (kg) 2550 3270 3295 3580 3600
Axle load full load 3375/385 4745/525 4755/535 5450/630 5490/610
(front/back)(kg) no-load 1020/1230 1320/1950 1325/1965 1445/2135 1450/2150
Track(mm)
P Rear wheel 870 970
L4 Rear overhang(mm) 425 430 480
Overall size L1 Total length 3170 3410 3590
(with forks) B Overall width 1090 1150 1150
(mm) H6 Total height 2049 2079 2079
α/β Mast tilt angle (front /back) (°) 6/12
920×100
L3×W×T Fork size (mm) 920×122×40 1070×122×40
×40
Wa Min. Turn radius(mm) 1950 2265 2310
3575 3895 3940
(mm)
Min. Ground m1 Mast 110 135 135
clearance(mm) m2 Frame 100 140 140
Max.Lifting full load 480 500 550
speed(mm/s) no-load 500 530 580
H1 Overhead guard height(from
1025 1009
face of seat)（mm）
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Model LG30D LG30DT LG35D LG35DT LG40D(T)
Rated load (kg) 3000 3500 4000
Self-weight of whole forklift
4065 4070 4418 4320 4919
(kg)
Axle load full load 6300/700 6360/700 7120/798 7032/782 8027/892
(front/back)(kg) no-load 1600/2400 1628/2442 1768/2650 1728/2592 1969/2950
Track(mm)
P Rear wheel 970
L4 Rear overhang(mm) 522 530
Overall size L1 Total length 3775 3775 3993
(with forks) B Overall width 1225 1225 1225
(mm) H6 Total height 2100 2100 2343
α/β Mast tilt angle (front /back)
6/12
(°)
L3×W×T Fork size (mm) 1070×125×45 1070×125×45 1070×150×50
Wa Min. Turn radius(mm) 2450 2710
4155 4720
(mm)
Min. Ground m1 Mast 132 148
clearance(mm) m2 Frame 147 160
Max.Lifting full load 430 380
speed(mm/s) no-load 450 410
H1 Overhead guard
1000 1018
height(from face of seat)（mm）
6
7
Model LG20GLT LG25GLT LG30GLT
Power form Gasoline/LPG
Outline
Rated load kg 2000 2500 3000
Load center mm 500
Max. lifting height mm 3000
H2 free lifting height mm 140 140 188
Fork size L3×W×T mm 970×122×40 1070×122×40 1070×125×45
Mast tilt angle (α/β) deg 6/12
X front overhang mm 460 483
L4 Rear overhang mm 430 480 522
L1 total length
mm 3410 3590 3775
Size (including fork)
Overall dimension
B overall width mm 1150 1225

H1 mast height without
mm 2030 2077
being lifted
H6 total height mm 2079 2100
Wa minimum turning radius mm 2265 2310 2450
Ra minimum right angle channel
mm 4163 4238 4155
width
Maximal drive speed (full
Km/h 22/22 20/20
load/no-load)
Performance
Maximal lifting speed

mm/s 530/500 430/410
(no-load/full load)
Maximum gradability % 20
Self-weight kg 3270 3580 4031
Front wheel 7.00-12-12PR 28×9-15-12PR
Tyre
Rear wheel 6.00-9-10PR 6.5-10-10PR
S front track mm 960 1000
Track
Chassis P rear track mm 970
L5 axle base mm 1600 1700
M1 mast mm 135 132
Ground clearance
M2 frame mm 140 147
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Chapter 2 Use and safe operation precaution
The forklift driver and administrator must keep "Safety first" in mind, and operate forklift
safely according to Service Instruction and Driver Manual.
1. Transportation
Pay attention when transporting forklifts with cars or containers as follows:

1.1 . Apply the parking brake
1.2 . Fasten mast and counterweight with steel wire. Fill in the relevant position with wedge
firmly.
1.3 . Lift at the right place with “lift label” when lifting.
2. Deposit
2.1. Release coolant (but don’t release if the coolant is anti-rust or anti-freeze fluid)
2.2. Lay rust preventive oil on the on the non-lacquer parts, lay lube on the lift chain.
2.3. Put mast down to lowest position.
2.4. Apply the parking brake.
2.5. Fill in wedges under front wheels and rear wheels.
3. Preparative before operation
3.1 . Check the tightness of all the connecting parts and tight parts revealed.
3.2 . Check the hydraulic system for leakage, if there is enough oil in tank, enough lube in
lubricating system.
3.3 . Never smoke when checking fuel system and battery, and never refuel when running.
3.4 . Check if air pressure of tyre accord with prescription.
3.5 . Check if cooling system is normal.
3.6 . Check if there are bad junctures or short circuit in electrical system.
3.7 . Check free travel of footplates, and if all operating handles can reposition normally.
3.8 . Check steering system and brake system to ensure their agility and credibility.
3.9 . Check mast system to ensure carriage and mast can rise and fall smoothly.
4. Drive precaution
4.1 . Start of engine

【Put the switch at GAS or LPG—LPG forklift.】,then, Shift speed control lever in neutral
position, apply the parking brake, and then, turn on the power switch. The starter must not
work continuously over 15 seconds every time, start several times if the first startup fails,
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but the intervals should not less than 2 minutes. If it fails for three times, check whether
there are troubles in oil channel and circuit or not. If it is true, eliminate the troubles and
then start again, don’t start up it continuously for a long time. The engine should run idle
for about 5 minutes after startup, don’t use it with full load until the coolant temperature in
engine reaches 65℃.
4.2 . Check before/after operation
When running the engine idle, check if the reading of coolant temperature meter, oil
pressure meter, current meter and fuel oil meter accord with prescriptions, check free
travel of foot pedal, check parking brake system and service brake system. Test lifting and
falling of masts, front and back tilting, turning and braking. Loosen the parking brake
system after making sure all the troubles are eliminated.
4.3 . Stopping of engine
Idle the engine about 5 minutes so that it can be gradually cooled, control flameout guy
(put the ignition switch of electromagnetic flameout device at OFF position) ,【hold the
oil and gas switch in the middle OFF position--LPG Forklift】, and engine will shutdown.
【If the machine is stop because of lack of GAS or LPG during the operation, simply shift
the switch to a fuel position and restart--LPG Forklift】.
5. Safety precaution
Safety
5.1. Forklift is special vehicle, only the driver with license can drive it. Maintenance of
forklifts should be operated by educated and eligible workers in order to make sure
forklift can be used normally.
5.2. When operating the forklift, workers should wear shoes, hats, clothes, and gloves that can
protect their safety.
5.3. When the distance between the barycenter of cargo and fork arm is 500mm, the max
capacity is the rated load, the load should be within prescription.
5.4. When the distance is further than 500mm, the load should decrease according with the
load graph. Otherwise, never load.
5.5. The forklift is fit for flat and firm road. Grease on the road must be erased.
5.6. Before and after using the forklift, check it daily so as to operate it without troubles next
time. When the forklift is working, if abnormal situation is found, stop the forklift to
check it. Don’t operate it until the failure is eliminated.
5.7. Keep the handle still when operating the other handle. Don’t manipulate handles unless
you sit on the driver’s seat.
5.8. Don’t load incompact cargo. Carry big cargo carefully.
5.9. The forklift with attachments ordered specially can be used more extensively. But the
attachments will reduce the load and stability of the forklift. Don’t use such fixture in
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other aspects. Read our additional direct and comply with our request, don’t rebuild
them privately.
5.10. Don’t pluck up the embeddings (if necessary, compute pluck up force firstly).
5.11. Adjust the distance of tines according with the cargo when carrying. The load should be
shared by two forks lest the cargo surge to one side. Don’t load anything with one tine.
5.12. If a load blocks the driver’s view, travel in reverse.
5.13. Put the fork to the ground when loading. After the forks inserting into the cargo, the
fork arm should contact the cargo, and then, tilt the mast to utmost position. Travel till
the forks raise 200mm-300mm above.
5.14. Make sure there are no persons below the fork when raising or falling the cargo. Don’t
raise person with forks.
5.15. Make sure the mast is vertical and the brake system is applied when operating.
5.16. When raising cargo, step the accelerator properly according to cargo weight and then
handle the lever.
5.17. The cargo drops because of the . Reduce the speed of engine and pull the lever slowly
to make the cargo drop gradually.
5.18. The moving of implement valve lever can control the speed of raising or landing of
cargo. The muzzle velocity should be small no matter raising or landing.
5.19. Apply the brake before tilting mast. When tilting forward, reduce the accelerator and
tilt slowly so as to prevent cargo from slipping.
5.20. For the forklift with high raising travel mast, tilt back as possible as it can, and tilt
within the permitted minimum range when loading or unloading. Never travel or turn
with the fork raised.
5.21. Prevent cargo above from falling when driving a forklift with high travel mast over 3
meters, adopt safety methods if necessary.
5.22. The overhead guard is used to protect the driver from objects’ falling. And serious
accidents may happen if it is flexible, removed or rebuilt.
5.23. The load backrest prevents cargo loaded slipping to operator. Accident may happen if it
is flexible, removed or rebuilt.
5.24. The height of cargo loaded should less than that of load backrest, if not, the cargo may
slip to operator.
5.25. Be careful of the influence of wind when working outdoors.
5.26. Be careful and travel slowly when traveling at dock or temporary plank.
5.27. When traveling with load, never tilt the mast forward, never load and unload cargo, or
never apply brake abruptly, otherwise, the cargo may slip.
5.28. The forklift should travel into cargo storage area at a low speed; also, notice if there
are bulgy solid objects lest the tyres are stabbed.
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5.29. Pay ATTENTION to people, barrier and/or pit on the ground and the overhead
clearance;
5.30. Never throw out hands, feet and any parts of body out of cab, keep driver alone in cab.
5.31. Never turn and travel transversely when working on a slope, or else, the forklift may
turn over. Travel forward when uphill and backward when downhill if the ramp is steep.
Apply the service brake system when downhill. Never shut off the engine when
traveling on slope.
5.32. Start, turn, run, brake and stop smoothly, speed down the forklift when turning on dank
or slick road.
5.33. Never start, turn, run, brake or stop abruptly. Incorrect operation may make the forklift
turn over. If an accident happens, keep calm and don’t jump down, grasp the steering
handwheel and incline to the contrary direction of turning over.
5.34. Never stay on truck and shut off the engine when refueling. Never inflame when
checking battery or oil level.
5.35. Tilt back the mast when stopping or running the engine idle. Never leave the forklift
out of sight in this case, and never leave the seat with cargo raise above.
5.36. Refuel after working for one day, which can prevent humidity in oil tank from
coagulating to mix with oil.
5.37. Never shift in reverse gear before the forklift stops, otherwise components or parts
could be damaged.
5.38. Apply the parking brake system, lower the fork to ground, shift in neutral position, and
turn off the engine or power switch before leaving the forklift. Apply the parking brake
when stopping on the slope, fill wedges under wheels if stopped for a long time. Never
park the forklift on steep slope.
5.39. Do not open the radiator cover randomly when engine is still hot.
5.40. The pressure of Mutiple-way valve and safety valve is adjusted by factory. Never
adjust it lest high pressure damage the hydraulic system and parts.
5.41. The air pressure of tyres should accord with prescribed “Tyre pressure”.
5.42. When traveling on flat and firm road, the max noise out of forklift is 89db（A；）by the
method of sound power method(7 meters from forklift), but the value will fluctuate
with the change of road condition.
5.43. The driver will feel the vibration of forklift with traveling on flat and firm road, and the
degree of vibration will fluctuate with the change of working of environment.
5.44. The emission of exhaust gas of forklift accords with prescription of Chinese
government, smoke density of the diesel engine made in china should less than 5 Bosch,
the CO thickness of gasoline engine made in china should less than 5%, the HC
thickness should less than 2500PPM, if engines made in other countries is used, the
12
emission of exhaust gas accord with Euro Ⅱ emission standard. The harm of exhaust
gas is inevitable, never drive forklift in airtight space, for the exhaust gas may choke the
driver.
5.45. Pay attention to and be familiar with the function of labels on forklift.
5.46. The forklift is used below an altitude of 1000km, and the temperature should be
between -15℃ and 35℃. Please operate carefully in other bad condition.
Complementarity
Complementarity:: The drivers should get on and off the forklift by the left side. Never get
on or off on the right hand side.
6. Daily Maintenance
6.1 Maintenance summary
6.1.1The forklift need be checked and maintained termly. Some key parts should be
changed by request regularly.
6.1.2 Please use our parts. Don’t use different type of oil when refueling or changing oil.
6.1.3 Report to managers if troubles are found. Never use the forklift before it is repaired.
6.1.4 Never repair the forklift without eligible training.
6.2 Startup
6.2.1 Quantity of hydraulic oil: the oil level should be at the middle position of scale.
6.2.2 Check if pipes, joint, pumps and valves leak or be damaged.
6.2.3. Check service brake system: the travel of brake footplate should be within 40mm, the
clearance between front soleplate and footplate should be over 20mm.
6.2.4 Check the parking brake system: the forklift can be parked at 20% slope when parking
brake handle is pulled to the limit.
6.2.5 Meters and lights: check if meters, lights, joints, switches and circuits can work
normally.
6.3 Cooling system precaution
6.3.1 When the radiator is boiled or the coolant temperature is too high, don’t open the
radiator cover immediately. If the radiator must be opened, slow down the speed of
engine, screw the cover of radiator, and take the cover after a while less the coolant burst
forth to scald the operator. When screwing the cover, please screw to the limit, otherwise,
the pressure could not accord with the prescription.
6.3.2 The there is a riser tank at the left side of engine with “FULL”, “LOW” labels, the level
of antifreeze should between the two scales. Fill same type of antifreeze if there is any
13
leakage or vaporization. Don’t change antifreeze with seasons. After a year, filtrate it and
then used continually.
The antifreeze is venomous, please label “danger” when depositing and put it in a safe
place. If eat it inadvertently, please try to throw up and go to hospital to see a doctor.
6.3.3 Clear the smudge on the radiator termly according to different conditions. Scour,
compressed air or high pressure water (Pressure should be no more than 4kg/cm2.) are all
available.
6.4 Oil, grease and antifreeze
Specification
Description Quantity
Domestic Made Overseas Made
Gasoline 90# JISK2202/2# 52L
Choose by user’s manual of diesel
JISK2204/2#(commonlyarea
engine, or accord with GB252-81:
Diesel oil ) 52L
-10～-35# for winter and 0# for
JISK2204/3#（cold area）
summer
LPG
(liquefied
40L
petroleum
gas)
Choose by use’s manual of diesel
engine, or accord with the GB5323-85 SAE10W(winter)
Lubricant 7L
standard and strict degree of working SAE30（summer）
condition
Hydraulic oil N32# or N46# ISOVG30 34L
Transmission
6# or 8# SAD10W 7L
oil
Brake fluid 85W/90 SAE85E/90 7L
Brake fluid DOT3 synthetic brake fluid 1.5L
Lubricating
3# lithium based grease 170 JISK2202/2#
grease
Water or FD-2 type -35℃ antirust or
Antifreeze Full
anti-freeze fluid
The filling of oil, grease and antifreeze should be executed according with relative
automobile standard. Deal with the poisons by relative laws.
14
6.5 Lubricating system
15
Chapter 3 Forklift Structure, principle, adjustment ,maintenance
It’s important to know the structure, principle, adjustment and maintenance in order to
make the forklift in the best performance .When the forklift has trouble, the serviceman
must be qualified, specified parts must be used.
1. The power system
1.1 The engine
This Manual includes petrol engine and diesel engine, the engine is integrated with the
transmission device, the engine support is connected with the frame via rubber gasket to
reduce vibration.
The power system consists of the diesel engine, the fuel system, the cooling system and
the exhaust system. The engine is assembled on the frame by some rubbers which could
absorb vibration. The engine, the torque converter, the clutch, the transmission and the
axle are as a whole.
Figure1.1 Engine installation diagram
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1.2 The engine parameters and applicable models
Diesel engine
Engine model
490BPG orA190BPG ISUZU 4JG2
Rated power/rotate speed kw(ps)/r.p.m 35(47.5)/2650 44.9/2450
Rated torque/ rotate speed N.m (kg.m)/r.p.m 145(14.8)/1900 184.7/1700
Number of the cylinders-diameter of the
4-90×100 4-95.4×107
cylinders ×stroke mm
Compression ratio 18 20.5
Overall displacement L 2.54 3.059
Grease capacity L 6.0 5.2
Operating weight kg 260 240
Overall dimension mm (length × width ×
751×565×704 718.6×572×745.5
height)
FD20(T)/FD25(T) FD30T/FD35T
FD30(T)/FD35(T) LG30DT /
Applicable models
LG20D(T)/ LG25D(T) LG35DT
LG30D(T)/ LG35D(T) LG15D / LG40DT
Engine model K21 K25

Rated power/rotation speed kw (ps) /r.p.m 31.2/2250 37.4/2300
Rated torque/rotation speed N.m (kg.m)/r.p.m 143.7/1600 176.5/1600
Cylinder number-cylinder diameter*stroke
4-89×83 4-89×100
type mm
Compression ratio 8.7 8.7
Total displacement L 2.065 2.488
Lubrication oil capacity L 3.5 3.5
Weight kg 245 245
Overall size mm L×W×H 709×589×683 709×589×683
LG20GL/LG25GL LG30GL/LG35GL
Applied model
LG20GLT/LG25GLT LG30GLT/LG35GLT
For the details of engine structure and adjustment, refer to the engine use and maintenance
manual.
17
1.3 Checking and adjusting of the engine
1.3.1 Air purifier

1) Take off the air purifier element;
2) Check the element dust and damage condition, if the element is dirty, blow it from inside
to outside with low-pressure air; if the element is damaged, it shall be replaced;
3) Clean the dust collector cover;
1.3.2 Oil purifier

A. Gasoline engine
1) Removal and replace filter with oil-filter wrench;
2) Remount the filter after injecting a few drops of fuel around seal ring of new filter and
screw it by 2/3 circle when the seal ring touches engine body.
B. Diesel oil engine
1) Removal and replace filter with oil-filter wrench;
2) Remount the filter after injecting a few drops of engine oil around seal ring of new filter
and screw it by 2/3 of circle when the seal ring touches engine body.
1.3.3 Radiator and auxiliary radiator

1) Check coolant level in auxiliary radiator
Check liquid level of auxiliary radiator; inject antifreeze to ordinary level if the level is
below the scale mark of “Low”;
The liquid level should be above “High” scale mark under condition of heat engine and at
the position of 2/3 volume under condition of cold engine.
2) Replace antifreeze
a. Turn off engine to wait for 30 min;
b. Remove radiator cap and loosen water drain cock of the radiator;
c. Loosen water drain cock of the engine to drain cooling liquid;
d. Screw down water drain cocks above;
e. Inject antifreeze to radiator, whose injection speed should be less than 21/min;
f. Start the engine to idle running for a while after full injection is completed, and then
check the level of auxiliary radiator, inject auxiliary radiator to ordinary level if the level
is low;
g. Screw down radiator cap and inject antifreeze at any time to keep level at the position of
2/3 volume.
3) Adjust tightness of fan belt

a. Loosen construction bolt of generator;
b. Remove generator to adjust tightness of fan belt. Press fingers on belt with the force of
10 kg and 10 mm down is in maximum.
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1.4 Fuel system
Fuel system is comprised of fuel tank, fuel filter, fuel sensor and fuel gauge for indicating
oil level.
1.4.1 Fuel tank
Fuel tank, which is on the left of frame, has been welded with the frame to one integrated
structure. Oil tank cover board, on which a fuel sensor for fuel level indicating is equipped,
locates at top plane of oil tank.
Fuel system
1.4.2 Fuel sensor

Fuel sensor is used for converting the fuel in the tank into current value.
1.4.3 Maintenance of fuel system
Carry out maintenance to fuel system every 100 hrs of running and clean oil tank every
600 hrs of running
(1) Fuel filter
Fuel filter equipped on fuel pump (gasoline models) or fuel tank (diesel oil models) is used
for filtering and cleaning the fuel supplying to engine. For diesel, fuel filter also can
separate water form fuel.
A.Gasoline engine
a. The whole filter should be replaced every 300 hrs of running;
19
b. Loosen spin wheel and removal cover;
c. Loosen screw nut and remove filter element;
d. Clean or replace filter element;
e. After remounting, start engine to enable the gasoline flowing into the oil cup of filter
so as to check oil leakage if any.
B.The whole filter should be replaced every 600 hrs of running;
a. Remount the filter after injecting a few drops of fuel around seal ring and screw it by 2/3
circle when the seal ring touches engine body.
b. Loosen water drain cock to drain water when warning indicator is lightened.
c. Note: Make sure water drain cock should be turned off after drainage is finished.
(2) Clean fuel tank.
Clean fuel tank every 600 hrs of running. For gasoline engine forklift truck, please pay
attention to fire prevention when cleaning.
1.5 Accelerator pedal
As shown in the illustration, the accelerator pedal equipped on the bottom floor is used for
controlling rotate speed of engine, which is connected with engine through connecting rod
and backstay cable.
Accelerator pedal
20
2 Clutch drive
Type Single piece-dry

Operating Foot pedal
Outside Dimension of the friction disc 275mm
Inside Dimension of the friction disc 175mm
Thickness 8.9±0.3mm
Area of the surface 345cm2
Weight 12.5kg
2.1 Overview
The clutch device is composed of clutch housing, friction plate, tappet and pressure plate
assembly, its function is to transmit and cut off the power from engine to transmission.
(Figure 2.1)
1.Press plate house

2. Friction disc
3. Press plate
4.Pressure spring
5. Spring
6. Hub plate
7. Drive shaft
8. Bearing
9. Declutch shift lever
10.Declutch shift bearing
11. Bearing sleeve
12.Supporting bolt
13.Nut
14. Declutch shift fork
15.Cover
Figure 2.1
21
2.1.1 Pressure plate cover and friction plate
The pressure plate cover is installed on the engine flywheel, the friction plate is installed
on the drive shaft of transmission between the pressure plate and flywheel with spline, the
release sleeve moves forward and the disengaging lever is pushed to make the pressure
plate leave the friction plate, so that the power from the engine can be cut off.
2.1.2 Clutch slave cylinder
The slave cylinder is installed at the left of transmission body. The cylinder is composed of
a piston, a spring and a push rod. Motion can be transmitted to the disengaging lever by
pushing the push rod.
1. Outlet oil valve
2. Cylinder body
3. Spring
4. Cap
5. Piston
6. Push rod
7. Dust cap
8. Locking nut
Figure 2.2 Clutch slave cylinder 9. Link rod
2.1.3 Clutch master cylinder

The master cylinder is installed on the clutch pedal, and the master cylinder is composed of
a piston, a spring, an oil reservoir and a push rod, the motion of pedal is transmitted to the
piston via the push rod, to turn the pedal force into the hydraulic pressure.
Figure 2.3 Clutch master cylinder
1. Link rod 4. Ring 7. Cap 10. Spring

2. Push rod 5. Stop plate 8. Spring 11. Cap
3. Dust cap 6. Piston 9. Valve rod 12. Cylinder body
22
2.1.4 Clutch pedal
The clutch pedal and brake pedal are installed in the same bracket, and the bracket is installed
on the transmission body, the motion of pedal is transmitted to the master cylinder, to turn the
pedal force into hydraulic pressure, the hydraulic pressure pushes the push rod of clutch slave
cylinder to transmit motion to the release yoke. The transmission with synchronizer
Figure 2.4 Clutch pedal
2.2 Maintenance
2.2.1. Adjustment of the clutch pedal

1) Remove the base board
2) Remove the locknut of the stop bolt
3) Screw the stop bolt left and right to adjust the
pedal height
4) Screw the locknut and assemble the base board
发动机
高度自由行程
吨位
图 2.5 Clutch pedal height
23
2.2.2. Replacement of friction disc
1. Remove the cover of the transmission housing
2. Step the clutch pedal, pull the press plate out with the pulling bolt.(Figure 2.6)
3. Turn the sliding bolt left to make the drive shaft get into the transmission.
4. Disassemble the fixed bolt of the press plate, and remove the friction disc.
5. Fit on the new friction disc, and ensure the long end of the spline is towards the
transmission.
Figure 2.6 pulling bolt
Note: Make sure the spline sleeve of the drive shaft is in the spline groove of the friction
disc.
6. The screw torque of the sliding bolt: 10.9-12.1kg.m
7. Mount the press plate on the flywheel
8. Step the foot pedal and take off the pulling bolt
9. Check the free stroke of the pedal and adjust it when it is necessary(The free stroke is
10mm.)
10. Keep 14mm between the tilt arm and the stop bolt.
Figure 2.7 adjusted the clutch slave cylinder
24
3 Mechanical drive system
Type Manual shift，sliding synchromesh
Mechanical Number of the gears Forward 2, reverse 2

transmission Forward gear1/ gear 2 3.253/1.407
Ratio
reverse gear1/gear 2 3.204/1.386
The reductor gear Spiral bevel gear
The reductor 2.5（1-1.5t）
Ratio
2.1（2-3.5t）
The reductor gear The vertical gear
5.7（1-1.5t）
The differential Ratio
6.182（2-3.5t）
The differential gear Common bevel gear
The oil volume 8L
136kg（1-1.5t）
The weight （without oil）
165kg（2-3.5t）
3.1 Summ ary

Summary
The mechanical drive device consists of transmission of synchromesh and differential.

The transmission with synchromesh refers to Figure 3.1
3.1.1 The transmission with synchromesh
(1) Power transmission of transmission
The mechanical transmission is primarily composed of a driving shaft, an output shaft, a
spindle and an idler shaft (used for reverse gear), each shaft is equipped with the gear with
one type of tooth or several different types of teeth, these gears realize gear shift through the
shifting lever via two sets of shift sleeve synchronizers, the power of engine is transmitted to
the driving wheel via the low speed gear, the differential gear and semi-shaft.
Neutral position (neutral)——the power from driving shaft is transmitted from the constant
mesh input gear and duplicate gear to high speed gear and low speed gear, because the gear
shift mesh sleeve of controlling speed and direction is at the neutral position, the spindle
output gear and output shaft won't transmit, so the power can't be output.
Gear shift position——when the gear shift lever is operated, the shift fork will drive the
mesh sleeve to move, and the gears will be meshed via the synchronizer. Dynamic
transmission procedure is as follows: Driving shaft → Input gear → Duplicate gear → High
speed or low speed shift gear → Synchronizer → Spindle → Synchronizer → Backward
gear or forward gear → Output gear → Output shaft realizes power output.
25
Power transmission order of forward 1 ：
○
1 -○
2 -○
3 -○
4 -○
11 -○
10 -○
8 -○
9 -○
12 -○
16 -○
15 -○
17 -○
18 -○
5 -○
21
Power transmission order of forward2：
○
1 -○
2 -○
3 -○
6 -○
7 -○
8 -○
9 -○
12 -○
16 -○
15 -○
17 -○
18 -○
5 -○
21
Power transmission order of reverse1：
○
1 -○
2 -○
3 -○
4 -○
11 -○
10 -○
8 -○
9 -○
12 -○
16 -○
15 -○
14 -○
13 -○
19 -○
20 -○
5 -○
21
Power transmission order of reverse2：
○
1 -○
2 -○
3 -○
6 -○
7 -○
8 -○
9 -○
12 -○
16 -○
15 -○
14 -○
13 -○
19 -○
20 -○
5 -○
21
Figure3.2 Power transmission
1.Input shaft 8.Joggle spacer 15.Joggle spacer

2.Input gear 9.Clutch drivehub 16.Clutch driven hub
3.Double gear 10.In-phase taper gear 17.In-phase taper gear
4.Double gear 11.Low speed gear 18.Forward gear
5.Output gear 12.Input shaft 19.Reverse gear
6.High speed gear 13.Reverse gear 20.Reverse gear
7.In-phase taper gear 14.In-phase taper gear 21.Output shaft
26
Figure 3.1 Dynamic transmission of transmission
1.Spring snap ring 13.O-ring 25.Forward gear 37. Taper roller bearing
2.Spring snap ring 14.Sliding bolt 26.Needle bearing 38.Shift lever
3.Ball bearing 15.Bearing support 27.Rollback gear 39.Shift fork
4.Spacer ring 16.Drive shaft 28.Clutch wheel hub 40.Neutral switch
5. Ball bearing 17.O-ring 29.Space ring 41.Shift fork
6.Drive gear 18.Drive gear 30. Needle bearing 42.Reverse light switch
7.Needle bearing 19.Lock nut 31.Shaft 43.O-ring
8. Combined bearing 20.Adjusting nut 32. Reverse gear 44.O-ring
9. Needle bearing 21.Taper roller bearing 33.Low speed gear 45.Collar
10. Space ring 22 Ball bearing 34.Cluth hub
11. Ball bearing 23.Bearing support 35.High speed gear
12.Oil seal 24.Steel ball 36.Ball bearing
27
(2) Synchronizer
The meshed gear can realize synchronized rotation via the synchronizer, when gear shift is
performed, gear won't impact each other, especially when the forward and backward gear
shift is performed, gear shift will be stable.
1.In-phase ring spline gear

2.In-phase ring
3.Spline gear11
4.In-phase taper gear
5.Joggle spacer
6.Spline Joggle spacer5
7.Spacer
8.Spring
9.Cluch driven hub
10.Fork
11.Joggleing gear
12.Gear tooth11
13.Joggleing gear
14.Gear tooth13
Figure3.3 Synchronizer
The synchronizer is primarily composed of (a) Synchro-cone, (b) Synchro-ring and (c)
Embedded block.
(a) Synchro-cone: Gear (11) (or (13)) is equipped with an involute spline of axial cone surface
(synchro-cone), and respectively combined with the synchro-ring ② And mesh sleeve ⑤
Via the conical friction surface and spline tooth.
(b) Synchro-ring: The snychro-ring is equipped with an orifice cone surface, the friction
surface is matched with the synchro-cone via this conical surface, the synchro-ring is
equipped with three slots distributed along the circle evenly, these three slots are centered
with the position of mesh sleeve spline and synchro-ring spline correspondingly, so as to
press to half of synchronization via the mesh sleeve spline ⑥.
(c) Embedded block: The projection in the middle of three embedded blocks is installed in the
spline slot of mesh sleeve ⑤, both ends are respectively embedded in the three
corresponding slots of synchro-ring, press the embedded block to the top of spline slot ⑥
via the two springs ⑧, and the outward spring force is convenient for the spline tooth of
synchro-ring to be the centering position.
3.1.2 Reductor and differential
The reductor is in front of the transmission to decrease the speed transferred from the
transmission and increase the torque from the output shaft then transfer the torque to the
28
differential. It consists of two spiral bevel gears of the different size on the output shaft and
a shaft of which the gear is small(shaft2 for short below),the bigger spiral bevel gear is
mounted on the shaft 2 of which both ends are supported by the taper roller bearing and of
which the clearance is adjusted by the gasket.
The differential is mounted on the front semi-housing by the ball bearing on both ends. The
front of the differential is connected to the axle house. The differential house consists of two
solar gears and four planet gears. The thrust washer is mounted between the transmission
housing and the gears to make the clearance of the gear pairs. The planet gear is supported
by gear shaftⅠand gear shaft Ⅱ. The gear shaft Ⅰis fixed by the parallel pin and the ring
gearⅠis fixed by the pin joint bolt on the differential housing.
The power from the transmission is decreased via the reductor and is transferred to the drive
wheels via axle shaft gear and the axle shaft.
The structure of the reductor and the differential refer to Figure3.4
Figure 3.4 the reductor and the differential
1.Ring gear 5.Gasket 9.Adjusting shim 13.Column bolt

2.Bolt 6 O-ring 10.Gear 14.Planet gear
3.Ball bearing 7.Bearing cover 11.Sleeve 15.Gasket
29
4.Side gear 8. Taper roller bearing 12.End bevel gear shaft 16.Gear shaft
30
4 Hydraulic drive system
Type Triplet-unit, single stage &two-phase

Torque
Torque ratio 3
converter
Setting pressure 0.5～0.68MPa
Type Inner mesh gear
Oil pump
Rate of flow 27L/min (2000rpm，1.5MPa)
Hydraulic type Power shift

transmission Speed ratio（forward/reverse） 1.35/1.35
Friction disc outer diameter × inner

125×8×2.7mm
Hydraulic diameter ×thickness
transmission Friction area 71cm2
Setting pressure 1.1～1.4MPa
Weight 165kg
Oil capacity 7L
Engine oil SAE10W

Oil type
6# hydraulic oil made in China
Summaryy
4.1 Summar
There are a torque converter and a drive system which consists of power shift transmission
on the hydraulic drive forklift which has the advantages below:
1) The inching valve ensures the inching operation at either high speed or low speed of
the engine;
2) There are 4 paper friction disc and steel plate which were specially developed on the
hydraulic clutch, which improves the abrasion of the friction pair;
3) The single stage overloading clutch in the torque converter improves the power
transfer efficiency.
4) There are good oil filter which extends the life of the torque converter.
31
Figure 4.1 Hydraulic drive device
1.Forward clutch 18.Safety valve cover 35.Output gear

2.Oil filter 19. Hexagonal socket 36.Idle wheel shaft
head plug
3.Reverse clutch 20.Plug 37. Single-row radial ball bearing
4. Single-row radial ball bearing 21.Elastic 38.Bearing nut
5.Seal ring 22.Speed shift arm 39. Single-row taper roller bearing
6.O-ring 23.Housing cover 40.O-ring
7.Oil supply pump assembly 24.Speed shift arm shaft 41.Oil seal
8.Oil seal 25.O-ring 42. Single-row taper roller bearing
9.Pump wheel 26.Woodruff key 43.Output shaft
10.Idle wheel 27.Elastic hole spacer 44.Support plate
11.Turbine 28. Single-row radial ball 45.Single-row radial ball bearing
bearing
12.Elastic board assembly 29. Bearing 46. Hexagonal socket head plug
13.Inching valve assembly 30.O-ring 47.Housing cover
14.Control valve ass'y 31.Spacer 48.Fixed bolt
15.Piston 32.O-ring 49.Reverse lamp switch
16.Spring 33.Idle wheel 50.Oil drain plug
17.Oil filling cover 34.Oil filter
32
4.2 The torque converter
The torque converter consists of a pump wheel, a turbine and an idle wheel. The structure
refers to Figure 4-2.
The pump wheel is driven by the input shaft. The oil ejects fiercely along the pump wheel
vane by the centrifugal force thus it transferred the torque to the output shaft. The oil which
departs from the turbine change the direction by the idle wheel, thus one part of the oil
returns to the pump wheel by certain angle. Meanwhile it arouses the reactive torque which
drives the idle wheel is part of the output torque. When the speed of the turbine approaches
near or to the input speed, the oil flow angle reduces and output torque decreases. At last,
the oil gets into the idle wheel vane at the opposite direction thus it makes the reactive
torque the opposite direction. So the torque of the input shaft is less than that of the output
shaft. In order to prevent this, we must make sure that the overrunning clutch in the idle
wheel could run freely when the reactive torque work oppositely.
This type of torque type ensures the efficiency and stability.
The torque converter of the drive part is connected with the engine flywheel by the elastic
board, and rotates with the rotation of the engine. There is full of transmission oil in the
torque converter. The drive gear which is attached to the pump wheel by two pawls drives
the oil pipe which provides the oil to the torque converter and the transmission. The turbine
is connected to the turbine shaft by the spline, and its power is transferred to the drive
transmission via turbine shaft.
Figure 4.2 Torque converter
33
4.3 Hydraulic clutch
The wet type multi-hydraulic clutch is installed on the input shaft of hydraulic transmission,
the pressure oil is distributed to the forward or backward clutch via the control valve, to
realize forward and backward gear shift. All the gears in the transmission belong to constant
mesh gear. Each clutch is composed of four spacers, four friction plates and a piston
assembled in phase-phase mode, the spacer and friction plate are separated, when gear is
shifted, the oil pressure acts on the piston, the spacer and the friction plate are compressed
mutually, form an adapter via the friction force so that the power from the torque converter
can be transmitted to the driving gear.
The power transmission procedure from torque converter to hydraulic transmission is as
follows:
Turbine → Input shaft assembly → Spacer → Friction plate → Forward gear or reverse gear
→ Output shaft.
Figure 4.3 Hydraulic clutch
1. Seal ring 8. O-ring 15. Seal ring 22. Stop ball

2. Bearing 9. Input shaft assembly 16. Seal ring 23. Piston
3. Stop collar 10. Seal ring 17. Seal ring 24. Spacer
4. Forward gear 11. End plate 18. Stop collar 25. Friction plate
5. Snap ring 12. Collar 19. Bearing 26. Spring
6. Snap ring 13. Reverse gear 20. Collar 27. Bearing
7. Spring seat 14. Bearing 21. Snap ring
34
4.4 Control valve, overflow valve and inching valve
4.4.1The control valve is installed inside of transmission cover, and the control valve includes
the control slide valve, constant pressure valve and adjusting valve;
4.4.2Constant pressure valve: The oil pressure used to control hydraulic clutch is between 1.1MPa
and 1.7MPa, the oil is distributed to the overflow valve and output to the torque converter;
4.4.3Adjusting valve: Installed between the inching valve and control valve, when the control
slide valve is opened fully, this valve will work to reduce the impact when the hydraulic
clutch is on.
Figure 4.4 control valve
1. Snap ring
2、O-ring
3. Inching valve rod
4. Snap ring
5. Spring
6. Spool
7. Spool
8. Valve body
9. Spring
10. O-ring
11. Cap
12. Seal ring
Figure 4.5 inching valve
35
4.4.4Overflow valve: the overflow valve connected with the transmission case can maintain the
torque converter oil pressure between 0.5MPa and 0.7MPa, to prevent loss;
4.4.5Inching valve: The inching valve is installed outside of transmission, the spool of valve is
connected on the link rod of inching pedal, when the inching pedal is stepped down, this
spool will move to the right, and the oil pressure of hydraulic clutch will be reduced in
short time so that the forklift can reach inching effect.
4.5 Transmission case
The transmission case is not only installed with the mechanism of input shaft and output
shaft, it's also used as oil tank, the bottom is equipped with an oil filter I (filter screen has
150 mesh) to filter and sucked oil of oil feed pump, the tube filter II, oil filling cap and oil
level device are installed on the case cover.
4.6 Oil feed pump
The oil feed pump is installed between the torque converter and input shaft, utilize the pump
wheel shaft to drive a pair of gear pump composed of internal gear, to supply oil to the
torque converter and hydraulic transmission.
Figure 4.6 Oil feed pump
4.7 The oil channel system of the torque converter
After the engine starts, the oil is piped from the oil filter tank (i.e. oil pan) by the oil supply
pump via the control valve, and divided into two groups, one for the for the hydraulic clutch,
the other is for the torque converter.
The oil for the hydraulic clutch flows into the torque converter vane via an priority valve(the
pressure is 1.1～1.4MPa ). The oil from the torque converter is cooled by the oil radiator,
36
lubricates the hydraulic clutch and returns to the oil tank.
The oil channel between the control slide valve and the transmission is closed when it is in
the neutral position. Turn the priority valve on at this time and the oil is piped to the torque
converter via the spillover valve. When the control valve is in the forwards gear or the
reverse gear, the oil channel between the control slide valve and the clutch are connected to
make each clutch work respectively. When one clutch works, the friction discs of the other
clutch are separated, which are lubricated and cooled by the cooling oil. When the inching
valve is compressed by the inching pedal, some or most of the oil led to the clutch is piped
to the oil tank via inching valve pushing rod. At this time the torque converter oil circuit is
the same as that in the neutral.
Figure 4-7 Oil channel system of torque converter
4.8 Towing of the breakdown forklift
The hydraulic forklift needs towing when it is broken down, please pay attention as follows:
1) Get off the axle haft from the front wheel.；
2) Apply the shift lever in the neutral。
37
4.9 Port fitting, oil pressure
pressure、 oil temperature measurement
Figure 4.8 Check oil temperature and oil pressure
38
5. Drive axle
Type Front wheel driving, fixed axle and frames, full-floating
1.5t 2t、2.5t
Tonnage
one-wheel two-wheel one-wheel two-wheel
Dimension of the tyre 2×6.5-10-10PR 2×6.5-10-10PR 2×7.00-12-12PR 4×7.00-12-12PR
Dimension of the rim 5.00S-10D 5.00S-10D 5.00S-12D 5.00S-12D
Pressure of the tyre 0.7MPa
Type Front wheel driving, fixed axle and frames, full-floating
3t 3.5t、4t
Tonnage
one-wheel two-wheel one-wheel two-wheel
Dimension of the tyre 2×28×9-15-12PR 4×28×9-15-12PR 2×7.00-12-12PR 4×7.00-12-12PR
Dimension of the rim 7.00WFB-15 7.00WFB-15 7.00WFB-12 7.00WFB-12
Pressure of the tyre 0.7MPa
Summaryy
5.1 Summar
The drive axle consists of the housing, the hub, the axle shaft and the brake. The housing is
whole casting, and the tyre is fixed on the hub by studs and nuts. The power is transferred to
the axle shaft via the differential and the hub drives the tyre at last. Each hub is fixed on the
axle housing by two taper roller bearings, so the axle shaft bears the torque of the hub only.
There is oil seal inside the hub to avoid dust and oil leakage.
The structure of the drive axle refers to Figure 5-1.
39
Figure 5-1 Drive axle
1.Axle housing 6.Taper roller bearing 11.Rim

2.Axle shaft 7.Hub 12.Adjusting nut
3.Wheel reductor 8.Taper roller bearing 13.Lock nut
4.Brake drum 9.Oil seal
5.Oil seal 10.Tyre
40
5.2 Assemble procedure of the wheel hub
procedure
1) Fill 100cc grease in the wheel hub and assemble

it on the shaft. (Figure 5-2)
2) Screw the nut with the torque of about 1kg.m
then turn 1/2 circle back.
3) Hung the spring balance on the bolt to measure
the primary torque of the hub and screw down
the bolt when achieve the prescribed value.
(Figure 5-3)
4) Fit the lock piece and the nut on, and then pull
the lock piece up to lock the nut. Figure 5-2 Filling grease
5) Assemble the tyre (Figure 5-4)
Please notice the following when assembling
the air rod, the nut cap and the rim on the tyre：
a) The air valve rod must be at the gap of the rim
and towards the outside.
b) The rim bolt end must be assembled towards
the outside.
Figure53 measure the initial torque
Rim bolt configuration
Figure 5-4 assembling wheels
1.Tyre 3.Rim bolt 5.Rim nut

2.Rim 4.Washer
41
6. Steering system
1-1.5T 2, 2.5t 3t, 3.5t, 4t

Type The rear wheel drive steering
Type of the redirector Cycloid hydraulic redirector
Model of the redirector BZZ1-100（taper orifice seal）
Type Double-action piston
Steering Diameter of the cylinder (mm) φ70
cylinder Diameter of the piston rod (mm) φ50
Travel of the piston (mm) 160
Rated pressure (MPa) 7 9
Radius of the steering handwheel (mm) φ380
Dimension of the tyre 5.00-8-8PR 6.00-9-10PR 6.5-10-10PR 6.00-9-10PR
Pressure of the tyre 0.7Mpa
ummaryy
6.1 Summar
The steering system consists of a steering handwheel, a steering shaft and a redirector. The
steering shaft is connected to the redirector via the universal joint，the connecting shaft is
connected to the steering wheel via the universal. The steering column can tilt forward and
backward to proper position. (Figure 6.1)
1、Steering handwheel
2、Redirector
3、Steering shaft
4、Universal joint
5、Connecting shaft
6、Steering column
Figure 6-1Steering control assembly
42
6.2 Cycloid full-hydraulic steering control units
The full hydraulic steering device (Figure 6.2) can transmit the pressure oil from the
diverter valve to the steering cylinder via a pipe according to the slewing angle of steering
wheel. When the engine is shutdown, the oil pump can't borrow oil and steering can be
performed manually.
Figure 6-1 Cycloid full-hydraulic steering control units
1. Limited post 4. Combined shaft 7. Rotor

2. Valve 5. Spring piece 8. Stator
3. Valve core 6. Connecting block 9. Valve housing
6.3 Check the steering system after reassembl ing the steering system
reassembling
1) Turn the steering wheel left and right to the limited position to check whether the force is
equal and the running is smooth.
2) Check whether the oil pipe and the turning direction are correct.
3) Jack up the rear wheel and turn the steering handwheel left and right slow several for
43
times to remove the air in the hydraulic pipe and the cylinder.
6.4 The steering system troubleshooting
Troubles Analysis of the troubles Troubleshooting

Malfunction or damage of the oil pump Replace
The steering wheel Block or damage of the shunt valve Clean or replace
can’t be turned Damage of the hose or the connector or block
Clean or replace
of the pipe
Low pressure of shunt valve Adjust the pressure
Air in the oil pipe Remove the air
Hard steering The redirector returning failure，locating spring

Replace the spring piece
piece brake or spring force deficiency
Adjust the flowrate of the
Leakage of the steering cylinder
distributor valve
Forklift travels Excessive steering flowrate Replace

S-shape or wobble Brake or no effectiveness of the spring Refueling
Oil lever of the tank is too low Clean or replace
Too noisy
Block of the oil inlet pipe or the oil filter Replace
Damage of the seal of the guide sleeve of the
Oil leak
steering cylinder or the pipe or the joint
6.5 Steering axle
The steering axle is the jointing structure of the case transect which consists of a steering
axle body, a steering cylinder, a connecting rod, a steering knuckle and two directive wheels.
The steering axle is crank block structure, the cylinder piston rod pushes the steering
knuckle via the connecting rod to turn. The steering axle is connected to the rear frame via
the buffer cushion.(Figure 6-3)
6.5.1 Steering spindles and king pins

Steering spindles equipped with king pins,taper bearings, dust proof spacers, o-rings were
fixed at the end of steering axle.One end of king pins fixed on the axle body by snap pin,
the other end fixed on the axle body by nut with split cotter, supported by the taper bearings
on the axle.
44
Figure 6-3 Steering axle
1.Steering axle body 14.Right steering knuckle 27.Nut M12

2.Plate 15.Steering axle hub 28.Bolt M14*45
3.Bolt M8*16 16.Wheel shaft cover 29.Spacer 14
4.Spacer 8 17.locking nut 30.Spacer 14
5.O-shaped ring 31.5*5.3 18.Cotter pin 5*50 31.Pin 10*30
6.Needle roller bearing 943/32 19.Steering knuckle spacer 32.Steering knuckle arm pin
7.Oil cup M10*1 20.Rolling bearing 30207 33.Snap ring
8.Steering knuckle pin 21.Rolling bearing 30211 34.Radial spherical plain bearing
9.Steering knuckle pin dust ring 22.Frame oil seal B85*110 35.Steering actuating cylinder
10.Steering thrust bearing shield 23.Hub bolt 36.Bolt M12*1.5*50
11.Thrust ball bearing 51208 24.Oil cup M6 37.Nut M12*1.5
12.Steering thrust bearing bush 25.Steering pull rod 38.Left steering knuckle
13.Adjusting shim 26.Locking screw 39.Steering axle hub nut
45
Figure 6-4 Steering spindle
6.5.2 Hub
Hub equipped with two taper bearings were fixed through the steering spindle, wheel
wedges in rim,inside of bearings conclude seal that can keep grease in the hub and steering
spindle,there are adjusting nut can adjust the degree of tightness of taper bearings .
6.5.3 Steering cylinder (Figure 6-5)
The cylinder is of double-action piston type, piston seal is the combined by the supporting
ring and the o-ring. The space between the cover and the piston rod is sealed by the
YX-ring along the shaft. The cylinder is fixed on the steering axle by the covers on each
ends.
6.5.4 Adjustment of the preload of the bearing of steering wheel
1) Infuse grease in the lumen of the hub,
the inner and outer bearings and the
hub cover, and the oil seals. See Figure
6-6.
46
Figure 6-6 Adjustment of the preload
2) Fix the outer of the bearing on the hub and assemble the hub on the shaft of the steering
knuckle.
3) Put the flat washer on and screw down the groove shape nut with torque of 206～235N.m.
Release the groove shape nut and then screw down it with torque of 9.8N.m.
4) Knock the hub lightly with wood hammer. Turn the hub for 3-4 rounds to ensure the hub
is tight.
5) Screw down the groove shape nut to make the groove aim at the hole of the cotter pin of
the steering knuckle.
6) Knock the hub lightly with wood hammer. Turn the hub for 3-4 rounds to insure smooth
running and measure the torque of the hub which is 2.94～7.8N.m.
7) Reverse 1/6 circle when the torque is more than the prescribed value, then measure the
torque again.
8) Lock the groove shape nut with the cotter pin when the torque achieves the prescribed
value.
Figure 6-5 Steering cylinder
1.Piston rod 10.Steel ball 6

2.Axial spring collar 65 11.Cylinder welding assembly
3.Ring 12.Guide sleeve
4.Hole elastic spring 70 13.Combination seal
5.O-shaped rubber sealing ring 14.Dust ring
6.O-shaped rubber sealing ring 15.Oil cup M6
7.Piston 16.Radial spherical plain bearing GEEW16ES
8.Supporting ring 17.Radial spherical plain bearing stop ring
9.Sealing leather ring
47
7. Brake system
Type Internal-expanding hydraulic two front wheel brake

The ratio of the pedal lever 5.66
Diameter of the general pump 19.05mm
Wheel type brake 1-1.5t 2-2.5t 3-4t
Type Double-servo including parking brake
Diameter of the subsidiary pump 22.22mm 28.58mm
Dimension of the friction disc（length,
279×48.5×5mm 324×60×7mm 348×76×8mm
width, thickness）
Area of the friction disc 135.3cm2×4 194.4cm2×4 164cm2×4
Inner diameter of the brake drum 254cm 310cm 314mm
Parking Internal-expanding two front wheel brake
ummaryy
7.1 Summar
It is two front wheels brake system which consists of a brake master pump, a brake and a
pedal.
The brake pedal is installed on the transmission via bracket. When the pedal is operated, it'll
push the rod to make piston move, so as to increase the oil circuit pressure.
Fig 7.1 Brake pedal (Mechanical)

48
Fig 7.2 Brake pedal (hydraulic)
7.1.1 The brake master pump
1. link rod
2. push rod
3. dustproof cover
4. piston
Figure 7-3 The brake master pump
The brake master pump consists of a valve holder, a unidirectional valve, a release spring
and leather cups. The end is fixed by a lock ring and lock steel wire and it is protected by a
rubber dust cover at the outside. The piston of the general pump is driven by operating the
brake pedal via the push rod. When depressing the brake pedal, the push rod pushes the
piston, the oil in the general pump returns to the oil tank via the oil-return orifice and
reaches the subsidiary pumps via the brake pipeline. Every piston of the subsidiary pumps
spreads to make the friction disc of the brake shoe contact the brake drum to brake the
vehicle. At this time the rear chamber of the piston is full of brake liquid from the fueling
hole and the oil input hole. When releasing the pedal, the piston reverses and the oil in the
subsidiary pumps returns to the brake master pump by the pressure of the return spring, the
spring returns to previous position, the oil in the brake master pump returns to the oil tank,
the pressure in the unidirectional valve is adjusted in accordance with the remained pressure
49
of brake pipeline and the subsidiary pumps, that make leather cups in the subsidiary pumps
fixed correctly to avoid leakage, and possible troubles when braking abruptly. The structure
of brake master pump refers to Figure 7-3.
7.1.2 Brake of the wheel
It is internal-expanding and hydraulic brake which consists of a brake shoe, a spring, the
subsidiary pumps and the board. The two brakes are fixed at each end of the front axle. One
end of the brake shoe is connected to the support rod and the other is connected to the
clearance adjusting and it is depressed to the board by the spring and the spring rod. There is
parking brake rod on the main brake shoe and there is adjusting rod of the auto clearance
regulator on the subsidiary brake shoe.see the fig 7-4,fig 7-5,fig 7-6
Figure 7-4 Brake of the wheel (1-1.8t)
1. Piston mandril 10. Parking brake rod 19、E-ring

2. Cover 11. Spring rope 20. Brake steel rope
3. Piston 12. Spring press rod 21. Spring press rod
4. Spring 13. Spring press seat 22. Spring press seat
5. Leather bowl 14. Spring 23. Parking brake rod
6. Cylinder 15. Return spring 24. Primary brake
7. Subsidiary brake shoe 16. Pawl 25. Return spring
8. Return spring 17. Spring
9. Spring 18. Clearance regulator
50
Figure 7-5 Brake of the wheel (2t,2.5t)
1. Spring 11. Clearance regulator

2. Leather bowl 12. Spring
3. Piston 13. Brake steel rope assembly
4. Cylinder 14. Spring press cover
5. Piston mandril 15. Spring press rod
6. Return spring 16. Parking brake rod
7. Mandril 17. Parking brake push rod
8. Return spring 18. Subsidiary brake pump assembly
9. Adjusting lever 19. Return spring
10. Subsidiary brake shoe 20. Primary brake
51
Figure 7-6 Brake of the wheel (3t,3.5t)
1. Subsidiary brake pump assembly 13. Spring press seat

2. Spring 14. Spring press rod
3. Leather bowl 15. Spring press
4. Piston 16 Spring
5. Pump cover 17. Pawl
6. Piston mandril 18 Spring
7. Return spring 19 Clearance regulator assembly
8. Friction plate 20. Screw
9. Spring 21. Plate
10. Parking brake push rod 22. Return spring
11. Spring rope 23. Parking brake rod
12. Brake shoe 24. Brake steel rope assembly
7.1.3 Operation of braking device

Brake during the forward traveling, the primary brake shoe and auxiliary brake shoe are
respectively acted by two forces which are equal and opposite through operating the
brake wheel cylinder, so that the friction plate contacts the brake drum, the primary brake
shoe is pressed on the regulator by the friction between the friction plate and brake drum,
accordingly, the clearance regulator will generate a force bigger than operating wheel
cylinder to push the auxiliary brake shoe, to make the upper end of auxiliary brake shoe
52
press the support pin with a big force, thereby acquiring bigger braking force. On the
other hand, the braking action during backward traveling will be performed in the
opposite direction, but the braking force is same as that of the forward traveling.
Fig 7.7 Operation of braking device (forward)
Fig 7.8 Operation of braking device(backward)
7.1.4 Parking brake

The parking brake adopts mechanical and internal expansion type and is installed on the
wheel brake, and it shares the brake shoe and brake drum with the foot brake. When the
parking brake handle is pulled, the brake handle will drive the hand brake pull rod via the
brake cable, this pull rod will push the hand brake pull rod rightwards via the pin of rotating
shaft, to make the brake shoe press to the brake drum.
Fig 7.9 Parking brake driver
53
7.1.5Clearance auto-regulator system
The self-regulating mechanism of clearance can maintain appropriate clearance of friction
plate and brake drum. The self-regulating mechanism of clearance only acts when traveling
reversely. Two self-regulating mechanism with different structures are included due to
different type.
Fig 7.10 2-2.5T Fig 7.11 1-1.8T, 3-3.5T
▲Clearance auto-regulator system

(a) 2-2.5t clearance auto-regulator system
The clearance auto-regulator system could
be taken into action only when reversing
the forklift. The subsidiary brake shoe and
the brake drum are contacted and run
together. The pull rod whirls right round
point A, see figure 5.3, point B will arise.
The pull rod whirls left by the spring
force when releasing the brake and point
B will decline.
When the clearance between the friction
disc and the brake drum is becoming
wider, the vertical distance of pawl
rotating of point B is longer. When the
distance is more than 0.4mm, one tooth of
the regulator is forked out, that makes the
adjusting rod longer and the clearance Figure 7.12 Clearance auto-regulator
narrower. system (2-2.5t)
Range of the clearance:0.4～0.45mm.
54
(b) 1-1.5t, 3-3.5t forklift clearance adjustment mechanism
When the forklift is braked at reversal, the
auxiliary brake shoe will contact the brake
drum and rotate together. Accordingly, the pull
rod will rotate rightwards surrounding A point,
and the pawl at B point will pull the regulator
gear.
After brake is released, the brake shoe will be
reset, the pull rod will rotate leftwards
surrounding A point and B point will fall. When
the clearance becomes bigger, the regulator will
be pulled with another gear.
Regulation range: within 0.25-0.4mm.
Figure 7.13 Clearance auto-regulator

system (1-1.5T,3-3.5t)
7.1.6 Parking brake lever

The parking brake hand lever is cam type. The
brake power could be adjusted by the regulator
at the end of the parking brake lever.
Adjust brake power
The brake force increases when rotate the
regulator clockwise and decreases when
anticlockwise.
The pull force: 20～30kg
Note: For the forklift of 2-2.5t, adjust by
screwing the bolt in the regulator.
Figure 7.14 Parking brake lever
55
7.1.7 Brake pedal regulation
(1) Shorten the push rod;
(2) Regulate the stop bolt and regulate the
pedal height;
(3) Step down the brake pedal to lengthen
push rod until the front end of push rod
is contacted with the piston of main
cylinder;
(4) Tighten the lock nut of push rod.
图 7.15 Regulation of pedal height
发动机
自由行程
吨位高度
制动微动
型式
1-1.5t
2-3.5t
▲Brake switch regulation
56
a. After the brake pedal height is regulated,
release the lock nut of brake switch;
b. Take off the plug to separate wire;
c. Rotate switch to make clearance A = 1mm;
d. Confirm the stop lamp is on when the brake
pedal is stepped down.
57
7.2 Maintenance
This section includes cylinder assembly of brake, re-assembly and regulation and regulation
of brake pedal, suitable for 1 - 1.5t and 3 - 3.5t forklift brake, although the regulator structure
of 2 - 2.5 brake is different, the maintenance method is basically same.
7.2.1 Disassembly of rim brake
1) Disassemble the positioning pin of auxiliary

brake shoe, regulating lever, regulator and
spring;
2) Disassemble the return spring of shoe plate;
3) Disassemble the fixed spring of primary brake

shoe;
4) Disassemble the main shoe, auxiliary shoe,

regulator and regulator spring;
58
5) Disassemble the wheel cylinder from the brake
tube, and then disassemble the mounting bolt
of wheel cylinder, to separate the wheel
cylinder from the bottom plate;
6) Disassemble the E-type stop ring of brake cable

on the bottom plate, and then disassemble the
mounting bolt of bottom plate, and
disassemble the bottom plate from axle;
7) Disassemble the dust shield of wheel cylinder,

and then push all components of cylinder.
7.2.2 Check the wheel brake

Check if there is any abrasion or damage
of the parts, and repair or replace the
disqualified ones.
1) Check if there is any rust on the surface
of the subsidiary pump and the piston,
then measure the clearance between the
piston and the cylinder.
Prescribed value: 0.03～0.10mm
The limited value: 0.15mm
59
2) Check if there is any abrasion or damage of
the subsidiary pump leather bowl and
replace the disqualified one.
3) Check the free length of the subsidiary
pump spring and replace the disqualified
one.
4) Check the thickness of the friction disc and
replace the excess attrited ones.
1-1.5t 2t, 2.5t 3-4t

The Prescribed
4.87 7.2 8
dimension
The limited
5.0 6
dimension
5) Check the inner face of the brake drum and

repair or replace it if it is damaged or excess
attrited.
1-1.5t 2t, 2.5t 3-4t

The Prescribed
254 310 314
dimension
The limited
256 312 316
dimension
7.2.3 Re-assembly of wheel brake

1) Immerse the wheel cylinder cup and
piston in the brake fluid, and then
respectively assemble the spring,
rubber cup, piston and shield in turn.
2) Install the wheel cylinder on the
bottom plate.
Tightening moment:
1 - 1.5t: 18 - 12N.m
2 - 2.5t: 14.7 - 19.6N.m
3 - 4t: 17.6 - 26.5N.m
3) Assemble the bottom plate on the

front axle
60
Tightening moment: 20.6 - 22.5N.m
61
4) Fill lubricating oil at each lubricating point.
a. Bearing surface of bottom plate
b. Support pin
c. Contact surface of shoe plate and compression
spring seat
d. Regulator thread and other rotating element
5) Assemble the brake steel cable assembly on the
bottom plate with an E-type stop ring.
6) Assemble the brake shoe on the bottom plate
with a positioning spring.
7) Assemble the compression spring on the hand
brake push rod and then assemble the push rod
on the brake shoe.
8) Assemble the guide plate of brake shoe on the

support pin, and then assemble the return spring
of brake shoe. Assemble the main shoe and then
assemble the auxiliary shoe.
9) Assemble the regulator, the spring of regulator,

ejector pin and return spring of ejector pin.
Note the following points:
a. The thread direction and installation
direction of regulator;
b. Regulator spring direction (the regulator
gear can't contact with spring);
c. Ejector pin return spring direction (the
spring hook at the support pin end shall be
fixed at the side opposite to the ejector
pin);
d. The lower end of regulating lever shall be
contacted with the regulator gear.
10) Connect the brake oil pipe on the wheel

cylinder.
11) Measure the inner diameter of brake drum and
the outer diameter of brake shoe, regulate the
regulator so that the difference between the
62
inner diameter of brake drum and the outer
diameter of brake shoe friction plate is 1mm.
63
7.2.4 Operation test of automatic clearance regulator
1) Firstly, regulate the brake shoe diameter so that it approaches the specified installation size,
regulate the lever by hand so that the regulator is rotated, when the hand is released,
regulate the lever to return the original position, however, the regulator gear won't rotate.
Note: Even though the hand is released, the regulator gear and the regulating lever will
return together, after the regulator is assembled on the vehicle, it can still work normally.
2) If the regulator can't realize the above operation when the regulating lever is pulled, the
following shall be checked.
a. Assemble the regulating lever, the ejector pin, the spring of ejector pin and the
compression spring seat reliably;
b. check whether the return spring of ejector pin and the regulator spring are damaged,
and then check the rotation of regulator gear and whether the meshing position is
worn excessively or damaged. Check whether the lever is contacted with the gear.
Replace the damaged component.
64
7.2.5 troubleshooting
Troubles Analysis of the troubles Solution
1. Oil leakage of the brake system Repair
2. Clearance of the drum is improper Adjust the regulator
3. Overheating of the brake Check if slide

Poor
4. Poor contact of the bake drum and the friction disc Adjust again
brake
5.Impurity on the friction disc Repair of replace
6. Impurity in the brake liquid Check the brake liquid
7. Improper adjustment of the brake pedal (the jiggle valve) Adjust
1. Case hardening of the friction or impurity on it Repair of replace
2. Distortion of the board or loose bolt Repair of replace

Noise of
3. Distortion of the brake drum disc or improper assembly Repair of replace
the brake
4. Abrasion of the friction disc Replace
5. Loose wheel bearing Repair
1. Oil stain on the friction disc Repair of replace
2. Improper clearance of the brake drums Adjust the regulator

Unequal
3. Malfunction of the subsidiary pump Repair of replace
brake
4. Damage of the return spring of the brake drum Replace
5. Deflexion of the brake drum Repair of replace
1. Oil leakage of the brake system Repair of replace
Poor 2. Improper clearance of the brake drum Adjust the regulator

brake 3. Air mixed in the brake system Deflate
4. Improper adjustment of the brake pedal Adjust again
65
8 .Lifting system
ifting
8.1 Summary
Lifting system is second roller vertical stretch; it is composed of inner and outer mast,
carriage and forks.
8.2 Inner and outer mast
8.1 mast
1.Lift chain 3.Fork 5.Inner mast 7.Tilt cylinder

2.Carriage 4.Bracket 6.Outer mast 8. Lift cylinder
The inner mast and outer mast are weld assembly. The bottom of the outer mast is installed
on the drive axle by support. The middle of it connects with the frame by tilt cylinder, and tilt
under the power of the tilt cylinder. The outer mast chan is like “C”, with master and side
roller wheel installed on its top. The inner mast chan is like “J”, with main and side roller
wheel installed on its bottom.
66
8.3 Carriage
The carriage rolls in the inner mast though the main roller wheel, the main roll wheel is
locked on axle by elastic collar, which is welded on the carriage, the side roller wheel is fixed
on the carriage by bolt, rolls along alar plate of inner mast and can be adjusted by adjusting
washer. Two fixed side roller wheel roll along the outside of the alar plate of inner mast to
control rolling clearance. Portrait load is undertaken by the main roller wheel, when the fork
rise to the top, the roller appears from the top of the mast. The transverse load is undertaken
by the side roller wheel.
8.4 Position of roller wheel
There are two kinds of roller wheel: main roller wheel and side roller wheel installed on outer
mast, inner mast, and carriage. The main roller wheel undertakes the portrait load, the side
roller wheel undertakes transverse load, making the inner mast and outer mast move freely.
Figure 8-2 Position of roller wheel
Note:
(a) Regulate the clearance of side roller to 0.5mm;
(b) Lubricate grease on the surface of main roller and contact surface of mast.
67
8.5 Maintenance
8.5.1 Adjustment of lift cylinder(Figure 8-3)

When exchanging the lift cylinder, inner mast or outer mast, the travel of lift cylinder need
be readjusted. The method follows as below:
1) Install the cylinder rod on the top of the inner mast without adjustment.
2) Raising the mast slowly to maximum travel of cylinder, and checking whether two
cylinders is synchronous.
3) Add adjustment washer between the first stop cylinder rod and the top of the inner mast.
The thickness of adjustment washer is 0.2mm and 0.5mm.
Figure 8-3 Adjustment of lift cylinder
4) Adjust the chain’s tension degree.

The maintenance of upper main roller and side roller of the internal and external mast
belongs to high-rise maintenance, safety shall be noted.
8.5.2 Adjust the height of carriage

1) Stop the car on flat ground and make mast vertical.
2) Make the bottom of the fork contact the ground, and adjust the top of the chain’s nut to
keep a distance A between the main roller wheel and the carriage.
68
3) Make the carriage on the floor and tilt it to the limited position, and adjust connector at the
top of the chain and the nut to equal the tension degree of two chains.
Forklift type A mm
1-1.5T 36-41
2, 2.5T 24-29
3-4T 19-24
Figure 8-4
8.5.3 Replacing roller wheel of carriage

1) Put a tray on the fork, and stop the car on flat
ground.
2) Put the fork and the tray on the ground.
3) Dismantle the connector at the top of the chain,
take off the chain from the chain roller.
4) Lift the inner mast. (Figure 8-5，①)
5) Travel reverse after the carriage departs from
outer mast. （Figure 8-5，②）
Figure 8-5
6) Replacing the main roller wheel
A、Dismantle all spring ring, take off the main roller wheel by tools, preserving the
adjusting washer.
B、Make sure the new roller wheel is same as the old one, install the new roller wheel on
the carriage and lock it by elastic collar .
69
8.5.4 Replacing the mast roller wheel（Figure 8-6）
1) Dismantle carriage from the inner mast by the means shown in 8.5.3.
2) Drive the car to flat ground, and underlay the front wheel 250-300mm.
3) Apply the parking brake, and fill the rear wheel up with sprags。
4) Dismantle the connecting bolt between lift cylinder and bottom of outer mast.
5) Dismantle lift cylinder and the oil pipe between the two cylinders. Don’t loosen the oil
pipe connector.
6) Lay down the inner mast; dismantle the main roller wheel at the bottom of it. The main
roller wheel at upside of outer mast will come out from the top of the inner mast.
7) Replacing the main roller wheel:
A、Dismantle the upside main roller wheel with tools, keep the adjusting washer.
B、Install the new roller wheel and the adjusting washer dismantled in stage A all
together.
8) Dismantle the fixed bolt between lift cylinder and inner mast.
9) Sling the inner mast, keeping the adjusting washer on top of the cylinder rod.
Figure 8-6
70
9. Hydraulic system
1-1.5T 2-2.5T 3-4T

Engine type 490BPG C240PKJ H25
Type Gear pump
Primary CBHz-F432-AL CBT-F431.5-AL CBT-F431.5-AL
model
pump H6 L φL φR
pt capcity 31.5ml/r
double slide valvefluid valvedividing valve and

Type
heeling latching valve
Multi-way
Adjustment pressure 17.5MPa
valve
Shunt pressure 7MPa(1-2.5t) 9MPa(3-4t)
Shunt volume 11L/min(1-2.5t) 13L/min(3-4t)
type Single-acting pistonTrip valve
Lift
Cylinder diameter φ56
cylinder
Travel 1495mm 3m heigh
Type Double-acting piston
tilt cylinder Cylinder route φ7
mileage 167mm
Hydraulic capacity 42L
9.1 Summary
Hydraulic system is composed of main oil pump, multi-way valve, lift valve, tilt cylinder
and pipe line, hydraulic fluid chamber is on left side.
9.2 Main pump
The main pump is a gear pump, which is directly driven by the engine’s power take-off.
The main pump is composed by pump body, one pair of gear, scaleboard and retainer ring,
pressure-equalizing bearing and special smooth technology is used to minimum the gear
backlash, the method depend on the oil between scaleboard and pump body which press the
scaleboard toward gear side.
71
1. pump body
2. drive gear
3. passiveness gear
4. front cover
5. back cover
6. scaleboard
7. seal ring
8. retainer ring
9. oil seal
10. Spring washer
Figure 9-1 Main pump
9.3 Multi-way valve and shunt valve

ulti-way
Two-piece multi-way valve is composed

of four valve bodies, two slide valves, a
secure fluid valve, and a shunt valve, the
four valve bodies is assembled by three
threaded studs and nuts and the heeling
slide valve is fixed with heeling latching
valve.
Figure 9-2 Multi-way valve
72
9.3.1 Operation of slide valve (take tilt slide valve for instance)
1) Neutral position
The high-pressure oil discharged from the oil pump returns to the oil tank via neutral
position.
2) Push into the slide valve
Close the middle channel, open the non-return valve and the oil from the oil inlet flows to
the cylinder interface B, the oil from the cylinder interface A flows to the oil tank via
low-pressure channel, and the slide vale can return to neutral position via return spring.
3) Pull out the slide valve
Close the neutral position, open the non-return valve and the oil from the oil inlet flows to
the cylinder interface A, the oil from the cylinder interface B flows to the oil tank via
low-pressure channel, and the slide vale can return to neutral position via return spring.
Figure 7.3
Figure 7.4 Figure 7.5
9.3.2 The structure of secure fluid master valve and shunt valve see as follows:
The secure fluid master valve is composed of independent valve A and pilot valve B, when
the multi-way valve turns, the Q chamber interconnects the operating mechanism(such as
lift cylinder, tilt cylinder), so the pressure oil crosses the fixed orifice D, E, then acts on
the pilot valve B. when the system pressure exceed the set pressure, the pilot valve B will
open up to reduce the pressure of F chamber, the master valve move towards right, which
73
make the pressure oil connect with hypopiesia route G to reduce the pressure of Q chamber
and assure the stability of the system’s pressure, also you can adjust the system’s stable
pressure by regulating the bolt H.
The structure of shunt secure valve is direct-acting flow-off, which make use of the principle
of liquid pressure balance with the power of spring to get steering system’s stable pressure.
The M chamber will connect with the high pressure oil route when operating the wheel
wheel. As the system’s pressure exceed the power of the spring, valve core N move toward
right, the pressure oil move through route G and connect with the hypopiesia oil route to
reduce the pressure of M chamber, which assure the stability of steering system’s pressure.
Also you can adjust the system’s stable pressure through regulating the bolt K.
Valve L is a balance slide valve, it can be moved left and right to change the width between
R and S by changing the flow rate and pressure continuously. That assures the balance of the
flow to chamber Q and to hydraulic steering system by outlet PS, shunting pro rata. A is the
fixed orifice.
Figure 9-6 Secure fluid master valve and shunt valve
9.3.3 Method of adjusting the secure valve’s pressure (Figure 9-7)

The user shouldn’t adjust the secure valve’s pressure, which has been set up when it is out the
factory, otherwise danger of system and the vehicle will be caused. If the oil pressure
departed from the set up value (17.5MPa), specialist should amend it by the method
prescribed by JB/T3300:
a. Unscrew the bolt of measured hole near the inlet of multi-way valve, then fix a oil pressure
gauge ranging from 0 to 20 MPa.
74
b. Operate the tilting lever, and then measure the
pressure when the cylinder reaches the end.
c. When the oil pressure is different from the set
value, loose the spillover valve’s nut and adjust
the pressure to the set value by turning the bolt
left and right. Turn left when the pressure is
higher and right when lower.
d. Adjuster lock nut.
1 - 1.5T 2 - 4T
Regulating
14.5 17.5
pressure
Figure 9-7 Method of adjusting the secure valve’s pressure
9.3.4 Operation of tilt self-locking valve

The tilt slide valve is installed with a
self-locking valve which is primarily used to
prevent vibration due to negative pressure in
the tilt cylinder, and avoid severe
consequence due to incorrect operation, for
general structure, the tilt slide valve can be
also operated to realize forward tilt after the
engine is stalls, after this tilt self-locking
valve is adopted, when the engine stalls, the
mast can't be tilted forward even though the
operating valve rod is pushed, and the
structure is as Figure below: Figure 9.8
The interface "A" and "B" of valve body are respectively connected to the back and front
cavity of tilt piston, when the slide valve is pulled out, the high pressure oil (P) will enter the
interface "A", the oil of back cavity returns to the oil tank (T) via "B", and the mast is tilted
backward.
When the tilt slide valve is pushed, the high-pressure oil will enter the interface "B", the
self-locking valve of slide valve will work with the help of high-pressure oil, "A" is
connected with low pressure, when the engine stalls or stops, there will be no high-pressure
oil making the self-locking valve of slide valve work, the interface "A" can't be connected
with low pressure, the mast won't tilt forward and negative pressure can't be formed in the
tilt cylinder.
75
9.4 The oil line of hydraulic system
The high pressure oil flow from the master pump to the multi-way valve, then it is divided by
the shunt valve into two parts: one is delivered to lift cylinder or tilt cylinder, and the other is
delivered to the steering gear in constant flow rate to control the steering cylinder. The high
pressure oil will return the oil tank through the route directly when the lift and tilt slide
valves are shifted in neutral position. As the lift slide valve is drawn back, the high pressure
oil goes through the shunt valve, and then pushes the piston rod below. When pushing the lift
slide valve, the lower lift cylinder piston connects with low pressure, then it will be pushed
down under the cargo and self-weight, the oil from lift cylinder goes through the throttle
valve and the speed is controlled. What operating the tilt slide valve, high pressure oil flows
into the front chamber of the tilt cylinder, while the other chamber connects with low
pressure, making mast tilt front or back.
Figure 9-9 The oil line of hydraulic system
76
9.5Multi-way valve control
9.5Multi-way
The multi-way valve is controlled by the joystick, all the joysticks are installed on one
connecting shaft, and the shaft is fixed on the dashboard via a bracket, and the joystick
controls the slide valve via a link rod.
Figure 9-10 Multi-way valve
Serial number Symbol Name Push the lifting lever forward and pull it
backward according to the arrow direction
of Figure, the mast will be lifted and
1 Up-and-down
lowered, push the tilt lever forward and
pull it backward, the mast will be tilted
forward and backward.
2 Tilt
77
9.6 Lift cylinder
The lift cylinder, composed of cylinder body, cylinder rod, piston, cylinder end etc, is a type
of single-acting piston. The bottom of the lift cylinder is fixed on the outer upright mounting
lift cylinder supporting by pin and bolt, while the top connects with the beam of the outer
upright mounting.
Piston is fixed on cylinder rod by springy wire, with oil seal and support ring fixed at the
housing washer of the piston.
There’s a trip valve under the lift cylinder which can take protective action if the mast rises
or the high pressure pipe breaks suddenly.
1 Bushing
2 Bolt
3 Washer
4 Gasket
5 Bolt
6 Washer
7 U-bolt
8 Washer
9 Nut
10 Support
11 Spacer
12 Bolt
13 Nut
14 Dust ring
15 Seal ring
16 O-ring
17 Cap,cylinder
18 Plug
19 Screw
20 Bearing
21 Bushing
22 Body,Cylinder
23 Piston rod
Adjusted
24
sleeve
25 Sanp ring
26 Wearing
27 Sanp ring
28 U-ring
Figure 9-11 Lift cylinder 29 Piston
30 Pin
78
The bottom of lifting cylinder is equipped with a cut-off
valve, when the burst resisting hose bursts suddenly, the
goods can be prevented falling too fast. The oil from the
lifting cylinder passes the cut-off valve and slide valve, the
oil holes surrounding the slide valve will make two cavities
generate pressure difference, when this pressure difference
is below spring, the slide valve won't work, if the burst
resisting hose bursts, big pressure difference will be
formed, so that the slide valve will move to block the
surrounding oil holes, only little oil can flow the hole at the
end of slide valve, and the fork will be lowered slowly.
9.7 Governor valve
The lift cylinder’s oil pipe is installed with governor valve (throttle valve) to control the
down speed of the fork when it is overloaded. The structure of it is shown Figure 7-7. When
the multi-way valve is at the “lift” position, , the high pressure oil from multi-way valve will
enter into lift cylinder through chamber A, B, hole C, D, E, F, and chamber G without
throttle; when the multi-way valve is at “down” position, the oil from lift cylinder flow
across the valve through chamber G, hole F, E, D, C and chamber B, A, causing pressure
difference between chamber A and B and opening of the globe valve (item 8). When the
difference exceeds power of spring 2, the spool 7 moves right to decrease the flow rate
because hole D, C become smaller, that means the floe rate through the throttle is lessened.
Figure 9-14 Governor valve
1.tie-in 4.Spacer 7.valve core 10.valve

2.spring 5.governor board 8.nylon ball
3.o- ring 6.valve housing 9.spring
79
9.8 Tilt cylinder
Double acting Tilt cylinder is installed on two sides of mast, its piston side connects with the
mast, and the bottom of it is connected with the frame by pin.
Tilt cylinder assembly is composed of piston, cylinder rod, body, bottom, guide sleeve and
seals, the piston and the cylinder rod are welded together, and the outer margin of the piston
is installed with a support ring and two Yx seal rings, the inner hole of the guide sleeve is
installed with sleeve pipe and Yx seal ring, limit ring, dustproof ring. The sleeve pipe
upholds the cylinder rod, the seal ring, limit ring and wiper scraper seal can avoid oil
leakage and dust, they surround upon the cylinder with “O”-ring.
When pushing the tilt valve forward, the high pressure oil comes in from the bottom to
push the piston forward, which tilt mast forward 6°; when pulling the tilt valve back, the
high pressure oil comes in the front and push the piston back until the tilt mast backward
12°.
Figure 9-14 Tilt cylinder
1.Pin 7.Ear ring 13.U-ring 19.Body,cylinder 25.BUshing

2.Bolt 8.Plug 14.O-ring 20.Body,piston 26.Nut
3.Washer 9.Screw 15.Guide sleeve 21.U-ring 27.Bolt
4.Fitting 10.Spacer 16.O-ring 22.Wearing 28.Washer
Adjusted shim Dust ring Snap ring O-ring
Fitting grease Snap ring Bushing Bushing
80
81
9.9 Hydraulic oil tank
The hydraulic oil tank is installed on the right case as the frame component, the oil tank is
equipped with hydraulic purifier to filter the impurity.
Figure 9-15 Hydraulic oil tank
Figure 9-16 hydraulic pipeline
82
9.10 Maintenance of main oil pump
1) Decomposition
Before the main oil pump is decomposed, clean it thoroughly. The disassembled components
shall be placed on the clean paper or cloth, prevent the components being dirt or damaged.
a Clamp the flange part of pump on the vice bench.
b Disassemble the connecting bolt ○
11 , pump cover ○
5 and pump box ○
1 .
c Disassemble the lining plate ○

6 , driving gear ○
2 and driven gear ○
3 .
d Disassemble the lock ring ○

7 and baffle ring ○
8 from the back and front end cover.
Note: If the lock ring isn't replaced, don't disassemble it from the front end.
9.17 Oil Pump
1.Pump body 4.front cover 7Seal ring 10.Snap ring

2.drive gear 5.back cover 8.Snap ring 11.Bolt
3.passiveness gear 6.Bush 9.oil seal 12.Washer
83
2) Check
Check the decomposed components and clean it with
petrol (not including rubber part).
a Pump check
If the contact length of pump cavity and gear is more
than 1/2 of perimeter, replace the pump.
9.18 Pump check
b Lining plate check

Check the contact surface of lining plate. If the
surface is damaged or thickness of lining plate is
below the specified value, replace the lining plate.
The specified value of lining plate thickness: 4.94mm.
9.19 Lining plate check
c Back and front pump cover

If the color of internal surface bush changes (brown)
over 150°, replace it.
d Check the driving and driven gear from back and
front. If the gear is worn severely, replace a pair. If
the dimension D is below the specified value,
replace it with pair.
D = 20.961mm. 9.20 Back and front pump cover
e Replace the lock ring, bush sealing element, stop

ring, oil seal and spring collar as required.
9.20 Gear check
84
3) Assembly
a Assemble a new lock ring and a new stop
ring on the front end cover of pump.
b Assemble the lining plate on the front end

cover slot, the oil inlet and oil outlet can't
be mistaken.
c Install the driving and driven gear on the 9.22 Seal ring of bush
front end cover.
d Assemble the lining plate at the gear side to
align the slot with gear point. The oil inlet
and oil outlet can't be mistaken.
e Assemble a new lock ring and a new stop

ring on the rear cover slot.
f Assemble the rear cover on the pump body,
and the oil inlet and oil outlet can't be
mistaken.
g After all components are assembled, tighten
the connecting bolt to the fixed torque 9 -
9.23 Lining plate
10kg.M.
9.11 Trial run
Perform trial run to make oil pump run-in and check whether running is normal. It’s better
to perform oil pump test on the test bench, and test can be performed according to the
following procedures on the forklift:
If the oil pump is worn severely or blocked due to hydraulic oil and will be decomposed for
repair, before the forklift performs trial-run, the hydraulic oil and purifier shall be replaced.
a. Assemble the pump on the forklift and assemble the pressure gauge on the pressure
detection port of multi-way valve.
b. Loosen the regulating screw of overflow valve, and run the pump for about 10 minutes
with 500-1000rpm. Ensure the oil pressure is below 10kg/cm2.
c. Increase the pump speed to 1500-2000rpm for about 10 minutes.
d. Maintain the pump running speed at 1500-2000rpm to increase the pressure by 20 -
30kg/cm2 every time, run the pump for 5 minutes until reaching 175kg/cm2, and then each
oil circuit operates for 5 minutes and replace the oil return purifier.
When the oil pressure is increased, the oil temperature, surface temperature of pump and
running sound shall be checked. If the oil temperature or pump surface temperature is
85
increased excessively, reduce the load to decrease the oil temperature, and then continue the
test.
e. Maintain the overflow pressure at 175kg/cm2 after test, and measure the flow. The oil
quantity is measured via the increase speed.
9.12 Debugging guide
Please find the reason and fix it upon the list below when the hydraulic system has
troubles.
1) Multi-way valve
Troubles reasons Troubleshooting

Slide valve clamping or Decompose, wash and replace
stagnation oil
Sliding plane break out Replace slide valve
The steering oil pressure
can’t reach the set value Spring collapse Replace spring
Oil hole jammed decompose and wash
Fluid valve misalignment Adjust the fluid valve
Slide valve clamping or
The lift oil passage Decompose and wash
stagnation
pressure can’t rise
Oil hole jammed Decompose and wash
The shock pressure rise Slide valve clamping stagnation Decompose and wash
slow Exhaust insufficiently Exhaust sufficiently
The oil passage pressure Slide valve clamping stagnation Decompose and wash
exceed the set data Oil hole jammed Decompose and wash
Can’t reach the set oil
Spillover valve misalignment Adjustment
mass
Spillover valve misalignment Adjustment
Noise
Sliding plane break out replace slide valve
replace the exchange the
Oil leakage (outside ) “O”-ring old or break out
“O”-ring
Spring collapse Replace spring
The set pressure is low
Sliding plane break out Adjust or replace the fluid valve
Oil leakage (inside) Sliding plane break out Amend the sliding plane
The set pressure is Slide valve clamping or
Decompose and wash
overhigh stagnation
86
87
2) Primary pump
Troubles reason Troubleshooting
Oil vent Oil level in box is low fill the tank

lack Oil pipe or purolator jammed Clean or replace according to the condition
Scaleboard break out
Supporting break out
Replace
Obturating ring, bushing sealing or
Pump closing ring is bad
pressure is Adjust the spillover valve’s pressure to the
Spillover valve misalignment
low set data by pressure gauge
screw down the intake side oil pipe
Air left in system Fill the tank
Replace the seal of oil pump
Oil pipe break out or purolator jammed Check the oil pipe or preserve the purolator
Working
Intake side is flexible and leak air Tightening
Causes
Oil viscosity is high Replace
noise
Air left in oil Find out the reason and take measures
Pump leak Obturating ring break out Replace

oil Pump break out Replace
88
10. Liquefied gas system
Liquefied gas system working principle:
When the LPG is stored in the steel cylinder, before engine is started, open the hand switch at
the outlet of steel cylinder. On the one hand, the impurity in the LPG will be removed via
filter/vacuum cut-off valve, on the other hand, when the internal combustion engine stops
running due to certain reason and the vacuum signal from the carburetor disappears, the internal
valve will be closed immediately to cut off LPG flow. When LPG flows to the
carburetor/pressure regulator, LPG will be vaporized to gas being heated, and the pressure can
only reach the pressure when the internal combustion engine runs via pressure reduction twice,
but the internal valve is still under normally closed state, and LPG can only flow out when the
internal combustion engine runs to cause vacuum, lots of heat will be absorbed during the
vaporization process, in order to prevent freezing of device, the hot water of engine must be
imported into the carburetor/pressure regulator. The gaseous LPG enters LPG mixer, and it'll be
mixed with clean air proportionally to become inflammable gas and enters the engine chamber,
and the engine can run normally and apply work externally. When the dual-fuel system selects
the gasoline, it's only necessary to open the fuel change-over switch and system will close LPG
supply system automatically via a solenoid valve, and the gasoline supply system can run
normally.
Liquefied gas system schematic diagram:
89
10.1 Liquefied gas system composition of LPG forklift
• Liquefied gas steel cylinder

• Filter and vacuum cut-off valve
• Solenoid valve
• Evaporator pressure regulator (also called low-pressure regulator)
• Mixer
• Cluster
• Steel cylinder bracket
10.1.1 Liquefied gas steel cylinder

The LPG steel cylinder belongs to the vehicle cylinder scope, the GB17259-1998
national standards shall be abided by domestically, it's composed of a cylinder and a
valve. In general, the steel cylinder shall have the four functions of discharging limit,
filling limit, safe discharging and liquid level display. If the excess flow valve is installed
internally, when lots of LPG is discharged due to damage of external LPG pipe, this
valve can be closed rapidly to limit flow; when LPG is filled, double check valve will be
installed internally, some steel cylinder is installed with 80% level hole, when the LPG is
charged to 80%
80%, white vaporific matter will come out from the level hole, and the double
check valve will operate to cut off and stop charging; the safety pressure relief valve is
set for certain injection starting pressure, when the pressure of the internal gas phase
structure exceeds this setting pressure, the internal gas can be discharged, to ensure safety;
the quantity in the cylinder can be observed via a float ball level gauge.
The structure of LPG steel cylinder is as follows:
90
10.1.1.1 Operation Manual of forklift LPG steel cylinder integrated valve assembly
a. Function
This assembly is composed of a CYSW314 steel cylinder, a CYFJ315-0I integrated valve,
a safety valve, a LPG gas filler of motor-vehicle, a gas outlet fast connector and
corresponding spare parts, it belongs to the fuel storage supply system of LPG forklift and
installed at the rear part of forklift. The main functions are as follows:
• Check valve
Check valve belongs to the manual valve controlling gas inlet and outlet pipeline.
• Charging limit valve
The charging limit valve will be closed when the LPG reaches 70%~80% of steel
cylinder capacity.
• Liquid level indicator
The liquid level indicator can display the liquid level of LPG in the steel cylinder.
• Flow-limiting valve
The flow-limiting valve will be closed when flow is too big (system has failure, flow
exceeds the design value).
• Safety valve
When the pressure in the steel cylinder exceeds the specified pressure, the safety valve
will be opened automatically to relieve pressure, protecting the safety of steel cylinder.
b. Main parameters
Working temperature: -40~+60℃; working pressure: 2.2MPa; opening pressure of safety
valve: 2.5±0.2MPa; maximum filling volume: 80% of steel cylinder volume.
c. Cautions for operation
• When the assembly fills LPG, open the check valve of inlet and close the check valve of
outlet, after gas is filled, close the check valve of inlet.
• When the assembly is installed on the forklift, it shall be installed fast. The direction
arrow on the end surface of steel cylinder shall be upward, and inlet and outlet check
valve shall be closed. Connect the inlet interface of forklift with the outlet interface of
assembly and fasten them, open the outlet check valve and check whether it leaks, if not,
it can be used.
• After the LPG is filled and used, leak check shall be implemented timely.
• The gas inlet filler shall prevent dust, after LPG is filled, screw on the dust shield timely,
to ensure leak tightness of the non-return valve of gas filler.
• The opening pressure of safety valve has been set and can't be changed randomly.
• The abnormal condition must be repaired by qualified unit without being regulated and
repaired randomly.
• Two metering modes can be used for this assembly to fill LPG LPG, namely volumetric
method and weight method. If the steel cylinder is filled with the weight method, the
cylinder must be placed vertically; if the steel cylinder is filled with the volumetric
method, the cylinder must be placed horizontally and the direction sign is upward.
91
If these requirements are not abided by, the steel cylinder can't operate normally and quality
assurance will be lost, and the manufacturer will not undertake any responsibilities for the
consequence due to installation and use without abiding by the above rules.
10.1.1.2 Operation Manual of forklift LPG steel cylinder

1. The steel cylinder filling, transportation, storage, use and inspection shall strictly abide
by the provisions of Safety Inspection Regulations for Gas Cylinders promulgated by
State Bureau of Quality and Technical Supervision.
2. The steel cylinder must be assembled and disassembled gently, mutual impact and impact
with external object are forbidden. The combination parts of steel cylinder shall be kept
in good condition which can't be disassembled, regulated and replaced with part
randomly;
3. The steel cylinder can be charged with the LPG conforming to GB11174 standard
repeatedly, and the maximum filling volume 80% of steel cylinder water volume;
4. The bracket must ensure the steel cylinder can be assembled fast, and the cylinder must
be assembled and positioned according to the upright mark on the cross section of steel
cylinder;
5. The steel cylinder can be filled at the LPG station with license issued by Bureau of
Quality and Technical Supervision. Random filling is forbidden;
6. When the new steel cylinder and rechecked steel cylinder are put into use initially, the
filling unit must pump the steel cylinder vacuum or use nitrogen gas for replacement
processing;
7. Before the steel cylinder is filled, it shall be inspected by special staff, if one of the
following conditions occurs, it must be handled firstly else filling will be forbidden;
a. Steel impression mark and color mark don't conform to the provisions or can't be
identified, and the medium in the cylinder isn't confirmed.
b. Accessories are damaged, incomplete or can't conform to the provisions.
c. There is no surplus pressure in the cylinder.
d. The inspection period is expired.
e. The cylinder has obvious damage via appearance inspection, and further inspection
is required.
f. The cylinder is filled initially, it's vacuum or the air is replaced by the nitrogen gas.
8. Before the steel cylinder is filled, the steel cylinder shall be positioned according to the
upright mark on the cylinder, the cylinder shall be placed horizontally and stably, close
the outlet check valve and open the inlet check valve. When the cylinder is filled, observe
whether the scale of level gauge is increased with the filled LPG. After the charging limit
valve operates, filling shall be stopped immediately and check whether the level gauge is
at normal position. After filling is completed, the inlet check valve must be closed;
9. Before the steel cylinder is used, it shall be checked whether it leaks or has other
abnormal condition, the cylinder can't be used with fault;
92
10. The steel cylinder can't be exposed to the sun, can't approach heating source and open fire,
and steel cylinder can't be heated by the heating source with temperature over 40℃;
11. The gas in the steel cylinder can't be used up, and 5% of residual gas shall be left;
12. The steel seal and color mark of steel cylinder can't be changed randomly;
The steel cylinder must be regularly tested by the testing unit approved by pressure vessel
safety supervision unit every 5 years according to the specified testing date.
10.1.1.3 Operation steps for LPG forklift to change cylinder

1. The canvas gloves must be worn when the steel cylinder is replaced, to prevent the
worker being injured due to gasification of leaked LPG.
2. The cylinder shall be replaced at wide space with fine ventilation, smoking and other
open fire are forbidden.
3. Check whether each part is in good condition.
4. Fix the gas cylinder reliably and the arrow (①) is upward.
5. Ensure the inlet and outlet check valves (②, ③) are closed.
6. Connect the input interface (⑤) of forklift with the gas outlet valve (④) and fasten them.
7. Open the outlet check valve (③) slowly.
8. The forklift can be only used after the valve is checked with no leakage, if the valve leaks,
close the outlet check valve (③) immediately and unscrew the input interface of forklift
(⑤).
10.1.1 Filter and vacuum cut-off valve
9. If the abnormal condition is found, report it for repair timely, random disassembly and
repair are forbidden. Meanwhile, the steel cylinder with abnormal condition shall be
isolated for storage.
93
10.1.2 filter and vacuum cut-off valve
The big-diameter filter is configured with high-capacity filtering area, and it's configured
based on the domestic condition that the air contains more impurity. The service life can be
extended and filtering precision can be enhanced effectively, the intake resistance is small,
the filter screen can remove the impurity in LPG to avoid blocking of downstream
vaporization equipment; meanwhile, when the internal combustion engine stops running
due to fault, the vacuum signal from the carburetor will disappear, and the internal valve
will be closed immediately, to cut off LPG flow, so it's the necessary equipment for LPG
conversion device.
10.1.3 Solenoid valve

The solenoid valve belong to the change-over device when the driver respectively uses two
kinds of fuel, namely gasoline solenoid valve and LPG solenoid valve, and they are
normally closed in general.
10.1.4 Switch ( illustration beside)

Switch is controlled by controlling the solenoid valve to achieve shifting the GAS and LPG
position. In the GAS position, gas solenoid valve is opened, LPG solenoid valve is closed,
gas oil way is opened and the gasoline engine is running. In the LPG position, LPG solenoid
valve is opened, gas solenoid valve is closed, LPG oil way is opened and the LPG engine is
running. In the OFF position, both gas solenoid valve and LPG solenoid valve are closed,
the engine is lack of fuel and will stop working.
10.1.5 Evaporator pressure regulator (also called low-pressure regulator)

The evaporator pressure regulator can regulate the LPG pressure from high pressure to
low pressure, reducing the 2.2Mpa LPG to 0~1KPa, and LPG will be vaporized to vapor
state being heated, meanwhile, pressure is reduced, but the internal valve is at normally
closed state, when certain vacuum suction is generated due to engine running, LPG can
flow out. The low temperature freezing under pressure reduction and throttling can be
avoided by utilizing the engine circulating water to heat the cylinder. The evaporator
pressure regulator belongs to the critical component of supplying sufficient fuel gas to the
mixer with change of engine operation condition, and it shall have the following
functions:
(1) Evaporation and pressure reduction function: the evaporation pressure reducer will
reduce the LPG pressure from 2.2Mpa to sub-atmospheric LPG.
(2) Flow regulation function: the output flow of evaporation pressure reducer is changed with
the change of engine operation condition, and sufficient fuel consumption of engine can
be provided. When engine runs, it'll be under negative pressure operating state.
(3) Gas heating function: because the pressure reduction of LPG has heat absorption
phenomenon, the throttling, heat-absorbing and temperature reduction phenomenon will
be generated when the high-pressure valve port is regulated, so as to influence the speed
94
of LPG evaporated from liquid state to gas state. In order to ensure fine heating stability
of fuel gas, the vehicle fuel gas reducer primarily adopts the method that the reducer shell
is heated by the engine circulating hot water to realize continual evaporation of LPG.
10.1.6 Mixer
Mix the vaporized LPG with air proportionally into the inflammable gas for engine run,
meanwhile, the idle speed air fuel ratio and power air fuel ratio are also regulated and
controlled via it. The mixer is installed on the gas inlet of engine carburetor, when the
engine is started and runs, the engine inlet manifold will generate vacuum, and then the
upper part of carburetor will form vacuum, when the vacuum level is higher than -0.2kPa-0.2kPa,
the air in the mixer diaphragm chamber will enter the gas inlet pipe of engine carburetor;
the mixer diaphragm chamber generates vacuum and the other one cavity is connected with
the air purifier, the mixer diaphragm will rise by overcoming the gravity of diaphragm stack
and elasticity of mixer spring under the air pressure, open the inlet valve seat and mixer air
valve seat, LPG and air are mixed in the mixing cavity and then enter the engine, and the
engine will run; the mixer diaphragm will move up and down according to the change of
vacuum level of engine carburetor gas inlet pipe, and the opening of air inlet valve port and
air valve port is changed accordingly, supply proper LPG to engine to form ideal mixture
with air. When the engine stops running, the pressure of gas inlet pipe of engine carburetor
is equal to air pressure, the air enters the mixer diaphragm chamber via the air hole, and air
pressure will reaches atmospheric pressure, accordingly, the mixer diaphragm won't bear
the air pressure difference, under the press of mixer spring, the natural gas inlet pipe will be
closed and liquefied gas won't enter the engine. When the engine backfires, one part of
backfire gas is discharged to the gas inlet pipe via the mixer air valve port, one part enters
the mixer diaphragm chamber via the air hole and expands in the air chamber, and then it'll
be discharged to the air via the mixer explosion-proof rubber cup, to prevent the mixer
diaphragm being damaged.
10.1.7 Wiring harness

The cluster will supply energy for normal operation of solenoid valve in the LPG system,
it's connected in the instrument cluster in parallel, the solenoid valve is opened and closed
via the key switch so as to realize fuel change-over.
10.1.8 Steel cylinder bracket

The steel cylinder bracket is installed on the balanceweight to fix the LPG steel cylinder.To
facilitate the replacement of cylinder, using rotating cylinder bracket. Periodically lubricate
the rotating bearings on the cylinder bracket to avoid failures.
95
10.2 Cautions for LPG forklift operation
1. Working place:
• Ventilation is fine, when necessary, use the blower fan to disperse the leaked liquefied
gas;
• Smoking and fire are forbidden in surrounding area, the heat source and the equipment
which will generate sparkle such as grinder and bench grinder and so on;
• The low-lying place such as trench is forbidden nearby, because the liquefied gas will be
probably accumulated;
• Prepare necessary fire-fighting equipment, fire extinguisher or water source;
• The emergency evacuation plan is made.
• 2. Handling of accident
• The people breathe too much liquefied gas, he/she will have faint, headache or body is
weak, the patient shall be moved to the well-ventilated place, when necessary, send the
patient to the hospital.
• If any part of body contact the LPG, it'll be injured due to freezing, and the injured part
shall be submerged in cold water when necessary, send the patient to the hospital;
• If the leaked liquefied gas is smelt, shut down the engine immediately and close the
manual valve of steel cylinder, check the leaking position and repair it.
If the forklift catches fire, the steel cylinder manual valve shall be closed immediately and
spray cold water on the steel cylinder to cool it so that it won't be exploded due to
expansion, if the steel cylinder catches fire, evacuate the staves nearby rapidly and inform
the fire fighter.
96
11. Electrical system
ummaryy
11.1 Summar
Electrical system is a one wire circuit with cathode ground strap connection. It is mainly
composed of part as follows:
1) Charging system
It is composed of engine, accumulator, charging indicator lamp, which supports the forklift
service equipment, and the voltage is DC12V.
2) Starting system
It is mainly composed of warm-up system (only for diesel engine), start switch, start guard
wire, start engine etc, its function is to start the engine.
3) Instrument system
It is composed of hour meter, fuel meter, coolant temperature gauge and signal control
lamp etc, it is the checking equipment of forklift. It uses combined meter which is installed
in U.S.A Curtis’s gas engine meter cassette mechanism
4) Lighting signal lamp
It includes various lighting, signal lamps and trumpet, buzzer etc.
Headlight:35W
Combination lamp (for turning/ showing width) 21W/8W
Rear combination lamp (for turning/ showing width /falling back): 21W red/8W red/10W
white
Caution light (option item) 21W
11.2 Description of operation
1) Starting
Shift the speed control lever in neutral position before starting the engine, otherwise, the
engine will not be started. This is because control box has the secure start guard function.
Rotate the start key clockwise to gear I, connect meters with the electrical power source,
the diesel engine will automatic preheat, preheat signal lamp will be lightened, 3.5m later,
the lamp wink automatically, the preheat time is control by the time relay to 13.5m.
2) Lamp switch: shift in gear I, front and rear lamp lamps for showing width light, shift in gear
II, head light lights, keeping front and rear lamp lamps for showing width bright.
3) Turning signal: when pulling back the turning lamp switch, front and rear combination lamp
at the left of forklift light, when pushing the switch, front and rear combination lamp at the
right of forklift light.
4) Brake signal: when needing to brake, step on the brake pedal, the rear combination light (for
braking, red) lights.
5) Backing-up signal: when the car needs a reversion, pull the forward-reverse lever, the rear
combination lamp (for falling back, white) lights, the buzzer will hoot.
6) Not charging signal: shift the starting switch to charging before starting the engine, the
97
charging signal lights, it will wink when the engine is fired; if the signal lights when the
engine is working, there are some troubles in charging circuit. In that case, stop the vehicle
to check up.
7) The oil pressure of engine signal: the signal lights when the engine is fired and the switch is
shifted in charging position, it will wink after the engine is started; when the engine is
working, if the signal lights, the pressure is too low and the lubricating is bad, stop the
vehicle to check up.
8) Water oil separator signal: the signal lights when the engine is fired and the switch is shifted
in charging position, it will wink after the engine is started. When the engine is working, if
the signal lights, the water level of the separator would be over the alarming level. Push the
pressure lever to drain the water until the signal wink.
9) Fuel gauge: it shows the oil level, when the indicator shows subter-2 pillar, the alarming
buzzer will hoot, which means the oil storage volume is low and you should refuel.
10) Coolant temperature gauge: it shows the temperature of cooling fluid of the engine.
11) Hour meter: it accumulates the engine’s working hours.
Appendix: Wiring harness diagram
Electric appliance circuit diagram
FD series engine wire harness
98
LG series engine wire harness
FD series instrument stand wire harness

99
LG series instrument stand wire harness
FD series left front roof steel grid wire harness
100
LG series left front roof steel grid wire harness
FD series right front roof steel grid wire harness
101
LG series right front roof steel grid wire harness
102
LG series rear headlight wire harness
103
FD series Diagram of electrical system
104
LG series Diagram of electrical system
105

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Available Formats

Preface

Thanks for selecting lonking forklifts.

Lonking (Shanghai) Forklift Co., Ltd.

B overall width mm 1150 1225

Maximal lifting speed

Pay attention when transporting forklifts with cars or containers as follows:

3. Preparative before operation

4.1 . Start of engine

6.3 Cooling system precaution

6.4 Oil, grease and antifreeze

1. The power system

1.1 The engine

Figure1.1 Engine installation diagram

Engine model K21 K25

1.3.1 Air purifier

1.3.2 Oil purifier

1.3.3 Radiator and auxiliary radiator

3) Adjust tightness of fan belt

1.4.2 Fuel sensor

1.5 Accelerator pedal

Type Single piece-dry

1.Press plate house

2.1.3 Clutch master cylinder

Figure 2.3 Clutch master cylinder

1. Link rod 4. Ring 7. Cap 10. Spring

Figure 2.4 Clutch pedal

2.2.1. Adjustment of the clutch pedal

图 2.5 Clutch pedal height

Figure 2.6 pulling bolt

Figure 2.7 adjusted the clutch slave cylinder

Type Manual shift，sliding synchromesh

Mechanical Number of the gears Forward 2, reverse 2

3.1 Summ ary

The mechanical drive device consists of transmission of synchromesh and differential.

Power transmission order of forward2：

Power transmission order of reverse1：

Power transmission order of reverse2：

Figure3.2 Power transmission

1.Input shaft 8.Joggle spacer 15.Joggle spacer

1.In-phase ring spline gear

Figure 3.4 the reductor and the differential

1.Ring gear 5.Gasket 9.Adjusting shim 13.Column bolt

Type Triplet-unit, single stage &two-phase

Hydraulic type Power shift

Friction disc outer diameter × inner

Engine oil SAE10W

1.Forward clutch 18.Safety valve cover 35.Output gear

Figure 4.2 Torque converter

Figure 4.3 Hydraulic clutch

1. Seal ring 8. O-ring 15. Seal ring 22. Stop ball

Figure 4.4 control valve

4.5 Transmission case

4.6 Oil feed pump

Figure 4.6 Oil feed pump

4.7 The oil channel system of the torque converter

Figure 4-7 Oil channel system of torque converter

4.8 Towing of the breakdown forklift

Figure 4.8 Check oil temperature and oil pressure

Type Front wheel driving, fixed axle and frames, full-floating

Dimension of the tyre 2×6.5-10-10PR 2×6.5-10-10PR 2×7.00-12-12PR 4×7.00-12-12PR

Dimension of the rim 5.00S-10D 5.00S-10D 5.00S-12D 5.00S-12D

Pressure of the tyre 0.7MPa

Type Front wheel driving, fixed axle and frames, full-floating